Title of Invention

A FILM HAVING AT LEAST ONE LAYER AND A PROCESS FOR PREPARING THE SAME

Abstract The subject invention provides a film having at least one layer comprising an interpolymer of ethylene and at least one comonomer selected from the group consisting of C<SUB>3-C<SUB>2<SUB>0 a- olefins, dienes, and cycloalkenes, wherein the interpolymer is characterized as having a high degree of processability, good optical perfomance, and good mechanical properties. The subject invention further provides film fabrication processes and polymer compositions which are useful in preparing the subject films.
Full Text The subject invention pertains to ethylene polymer compositions hich are useful in film applications. In particular, -he subject invention pertains to ethylene polymer compositions hich exhibit the processability of highly branched low density polyethylene, wile exhibiting improved mechanical properties, and to films prepared therefrom.
His-cortically speaking, highly branched low density polyethylene has found great utility in blown film applications, attributable in part to its unique processabilicy. Large amounts of long chain branching and a broad molecular weight distribution give this polymer the shear thinning and elt strength properties unmatched by heterogeneously branched linear low density polyethylene resins. Non-::Estonian shear thinning provides the high shear, low melt viscrsity for good extruder processability and low shear, high -elt viscosity for superior blow film bubble stability.
Low density polyethylene has found utility in a variety of film applications. Markets which require a combination cz high processability resins, but do not require high film clarity, include industrial liners, heavy duty shipping sacks, non-clarity rack and counter bags, mulch film, and rubber separators. Markets which require a combination of high processaDility resins and high clarity films include clarity liners, bakery films, shrink films, and garment bags.
The performance requirements vary depending upon the application, but include elements of (1) the polymer "extrudabilit-y" (high shear rheology) and melt strength (low shear rheology); (2) mechanical properties of the fabricated article; and 3) optical properties of the fabricated article. The actual performance requirements are given in terms of (1) the film bubble stability, polymer output rate (kg/hr) and

extruder periDrmance (pressure, melt temperature and motor amperes); ,2} strength of the fabricated article (such as tensiles, resistance to tear, resistance to puncture); and (3) clarity, haze and gloss of the fabricated article.
Heterogeneously branched ethylene/a-olefin interpolyrr.ers , which are referred to in industry as linear low density polyethylene (LLDPE), have likewise found utility in blown film applications. In many respects, such resins are preferred to low density polyethylene, as they lead to blown films exhibiting tear and toughnes__pr.Dp.ertaes. However, such polymers are -.ore difficult to process and have decreased optical properties, such as haze and clarity, than films prepared v;ith highly branched low density polyethylene.
In developing markets, demand for polyolefins which exhibit the processability of low density polyethylene is growing. However, the demand is currently outpacing the investment in new low density polyethylene plants. The industry v.-ould find advantage in olefin polymer compositions which are useful to prepare blown films which have toughness and impact prcperties comparable to heterogeneously branched "^^ l ethylene/alpha-olefin interpolymers, which exhibit the processabilit\" and optical properties of highly branched low t i-"" ■"" density polyethylene. Preferably, such polymer compositions would be produced in low pressure solution, slurry, or gas phase poiynerization reactions.
U.S. Patent Wo. 5,539,076 discloses a particulate polymer compcsition which is an in situ catalytically produced blend having a broad bimodal molecular weight distribution. Molecular weight distributions of 2.5 to 60 are broadly claimed, v;ith molecular weight distributions of 10 to 50 being preferred, and of 15 to 30 being most preferred.
U.S. Patent No. 5,420,220 discloses a film comprising a metallocene-catalyzed ethylene polymer having a density of from 0.900 tc 0.929 g/cm\ an I21/I2 of 15 to 25, an Mw/Mn of from 2.5 to 3.0, and a melting point ranging from 95°C to

135""C. A polyrr.er having an I21/I2 of 18 and an 1^/Mn of 2.6 is exemplified.
U.S. Patent Wo. 4,205,021 discloses a copolymer of ethylene and = C5-Cig a-olefin, which copolymer has a density of from 0.90 "o 0.94 g/cm^. The disclosed compositions are said to have long chain branching, and are described as preferably having two or more DSC melting points. U.S. 4,205,021 discloses the use of the disclosed polymers in blown films.
U.S. Serial No. 08/858,684 (PCT Publication WO 93/13,143), discloses the in-situ preparation of a blend of two ethylene poli.—.ers prepared with a constrained geometry catalyst, wherein each of the polymers is said to have a melt index (I2) of from 0.05 to 50 g/10 minutes. The polymers may be prepared in a single reactor with two active catalyst species, or rr.ay be produced in a dual reactor configuration with either the same or different constrained geometry catalysts being provided in each reactor.
The industry would find advantage in olefin polymer compositions ■.■;hich will usefully replace high pressure low density polyethylene, without requiring film fabricators to engage in significant reconstruction and retrofitting of their fabrication l^nes. The desired olefin polymer compositions should have crocessability and optical properties which are at least roughl\- equivalent to that of highly branched low density polyethylene. Preferably, the desired olefin polymer compositions ■.■rill further exhibit toughness and impact properties wh:Lch are improved over the properties of low density polyethylene- Preferably, such polymer compositions will be produced in low pressure solution, slurry, or gas phase polymerization reactions.
Accordingly, the subject invention provides a film having at least one layer comprising an interpolymer of ethylene and at least one comonomer selected from the group

consisting of C3-C20 a-olefins, dienes, and cycloalkenes, wherein the ir.terpolymer is characterized as having:
a. a density of from 0.910 to 0.930 g/cm^
b. a ir.elt index (I2) of from 0.2 to 10 g/10 minutes,
c. an I10/I2 of from 9 to 20, and
d. a molecular weight distribution, M„/Mn of from 2.1 to
5.
In an especially preferred embodiment, such a polymer will further have from one to two cirystallization peaks as determined by TREF, each occurring between 45°C and 98°C, with each having a CTBI of less than 18°C.
In one preferred embodiment, the interpolymer will have an I2 of from 1.; to 7 g/10 minutes. In a more preferred embodiment, the interpolymer will be prepared in two polymerization reactors, each of which contains a single site constrained geometry or metallocene catalyst. In such a more preferred embodiment, the interpolymer, upon fractionation by gel permeation chromatography, will most preferably be characterized as comprising:
a, frc~ 2 5 to 90 percent of a first polymer fraction
having a melt index (I2) of from 0.05 to 1.0 g/10
minuces, and a single crystallization peak between
45""C and 98°C having a CTBI value of less than 18°C as determined by TREF; and
b. from 10 to 75 percent of a second polymer fraction
having a melt index (I2) of at least 30 g/10 minutes,
and a single crystallization peak between 45""C and
gS^C having a CTBI value of less than 18°C as
determined by TREF.
In another preferred embodiment, the polymer will have an I2 of from 0.:5 to less than 2.5 g/10 minutes, an I10/I2 of at least 12.5, arid an Mw/Mn of from 2 .1 to 3 . 0. In this alternate preferred embodiment, the polymer will most preferably be characterized as having a single crystallization peak between

45°C and 93°C having a CTBI of less than 18°C as determined by TREF.
The subj set invention further provides a process for preparing a blown film comprising:
a. mel-ing an interpolymer to a temperature of 300 to
35C-F (149 to 177°C) , b- extruding the interpolymer at the rate of 15 to 50
lb, r.r (6.8 to 23 kg/hr) through a die having a 40 to 30 -.il [1 to 2 mm) die gap,
c. blcv;ing the film to into a bubble, at a blow-up-ratio
of 1.3 to 2, to form a 0.5 to 4 mil (0.01 to 0.1 mm)
gauge film, and
d. coding the film by means external to the bubble,
wherein the interpolymer is an interpolymer of ethylene and at
least one corr.rnomer selected from the group consisting of C3-C20
a-olefins, dienes, and cycloalkenes is characterized as
having;
i. a density of from 0.910 to 0.930 g/cm^ ii. a melt index [I-J of from 0.2 to 10 g/10
minutes, iii . an I10/I2 of from 9 to 20, and iv. a molecular weight distribution, M„/Mn of from 2.1 to 5. In an especially preferred process, the interpolymer employed v.-ill have from one to two crystallization peaks between 45-C =nd 98°C, each having a CTBI of less than 18°C, as determined by TREF.
The sub:ect invention further provides a process for preparing a blown film comprising:
a. r[iel~ing an interpolymer to a temperature of 300 to
40:^F (149 to 204°C} ,
b. ex-ruding the interpolymer at the rate of 15 to 5 0
lb rjT (6.8 to 23 kg/hr) through a die having a 40 to
30 -il (1 to 2 mm) die gap.

c. blo-rfing the film to into a bubble, at a blow-up-ratio
of 2 to 4, to form a 2 to 5 mil (0.05 to 0.13 mm)
gauge film, and
d. cooling the film by means external to the bubble,
wherein the interpolymer is an interpolymer of ethylene and at
least one comonomer selected from the group consisting of C3-C2Q
a-olefins, dienes, and cycloalkenes is characterized as
having:
i. a density of from 0.910 to 0.930 g/cm^ ii. a melt index (I2) of from 0.05 to 2.5 g/10
minutes, iii- an I10/I2 of from 12.5 to 20, and iv. a molecular weight distribution, M„/Mn of from 2.1 to 3. In an especially preferred process, the interpolymer employed will have from one to two crystallization peaks between 45""C and 98°C, each having a CTBI of less than ISX, as determined by TREF.
The subject invention further provides a polymer composition consisting essentially of an interpolymer of ethylene and at least one comonomer selected from the group
consisting of C3-C20 a-olefins, dienes, and cycloalkenes, wherein the interpolymer is characterized as having:
a. a density of from 0.910 to 0.930 g/cm".
b. a -elt index (I2) of from 0.2 to 10 g/10 minutes,
c. an I10/I2 of from 9 to 20,
d. a rr.olecular weight distribution, H^/Mn of from 2.1 to
5,
e. a molecular weight distribution, M„/Mn, as determined
by gel permeation chromatography and defined by the
equation:
CM /M ) w n 10 2
f. a gas extrusion rheology such that the critical shear
race at onset of surface melt fracture for the

interpolymer is at least 5 0 percent greater than the cri-ical shear rate at the onset of surface melt fracture for a linear ethylene polymer, wherein the interpolymer and the linear ethylene polymer comprise "he same comonomer or comonomers, wherein the linear ethylene polymer has an I . M /M and density within
2 w ci
"en percent of the interpolymer, and wherein the respective critical shear rates of the interpolymer and the linear ethylene polymer are measured at the same melt temperature using a gas extrusion rheometer.
In an especially preferred embodiment, the subject polymer composition will be characterized as having from one to
two crystallization peaks between 45°C and 98°C, each having a
CTBI of less -han 18°C, as determined by TREF.
These and other embodiments are more fully described in the following detailed description, wherein;
FIG"JRE 1 is a plot of the M^ versus melt index {I2) for polymers cf the Examples and Comparative Examples,
rIGVRE 2 is a plot of the M^j/Mn versus I10/I2 for polymers of the Examples and Comparative Examples, and
FIGVRE 3 is a diagrammatic representation of the calculation ci Crystallization Temperature Breadth Index, CTBI, for a general crystallization peak occurring in a Temperature Rising Eluzicn Fractionation, TREF, analysis. Test Methods
Unless c-herwise indicated, the following procedures are employed:
Densizy is measured in accordance with ASTM D-792. The samples are annealed at ambient conditions for 24 hours before the measurement is taken.
Melt index (I2)" is measured in accordance with ASTM D-
1238, condition 190°C/2.16 kg (formally known as "Condition
(E) ") .

Iio/ is -easured in accordance with ASTM D-1238, Condition 190°C/10 kg (formerly known as "Condition N").
Molecular weight is determined using gel permeation chromatograph;.- (GPC) on a Waters 150°C high temperature chromatographic unit equipped with three mixed porosity columns (Polymer Labcratories 10\ 10^, 10\ and 10^), operating at a system temperature of 140°C. The solvent is 1,2,4-trichlorobenzene, from which 0.14 percent by weight solutions of the samples are prepared for injection. The flow rate is 1.0 raL/min. ar.d the injection size is 100 microliters.
The mole~ular weight determination is deduced by using narrow molecular weight distribution polystyrene standards (from Polymer Laboratories) in conjunction with their elution volumes. The equivalent polyethylene molecular weights are determined by using appropriate Mark-Houwink coefficients for polyethylene 5Lnd polystyrene {as described by Williams and Word in Journal of Polymer Science, Polymer Letters, Vol. 6, (621) 1968) to derive the following equation:
^polyethylene ^ ^ * (^polystyrene"^•
In this equation, a = 0.4316 and b = 1.0. Weight average molecular weight, M^, is calculated in the usual manner
according to -he following formula; M^ = I. Wj_* M-i_, where w^ and M-L are the weight fraction and molecular weight, respectively, of the ith fraction eluting from the GPC column.
Melting temperature, crystallization temperature, and percent crystallinity are determined using differential scanning calcrimetry (DSC). Differential scanning calorimetry (DSC) data was generated by placing each sample (5 mg) in an aluminum pan, the sample was heated to 160°C, cooled at 10°C/min and "he endotherm was recorded by scanning from -30""C to 140°C at i;=C/min using a Perkin Elmer DSC 7. The DSC

exotherm (coding curve) was also recorded by scanning from 140
to -30 at 10=C min.
Percent :zrystallinity is calculated with the equation:
%C-[A/292 J/g) x 100,
in which %C represents the percent crystallinity and A represents the heat of fusion of the ethylene in Joules per gram (J/g) as determined by differential scanning calorimetry (DSC) .
Haze is -easured in accordance with ASTM D-1003.
Elmendorf tear is determined in accordance with ASTM D1922.
Tensile strength and toughness are determined in accordance with ASTM D638.
45° gloss is measured in accordance with ASTM D2457.
Dart impact (A, B) is measured in accordance with ASTM D-
1709
Percent elongation is measured in accordance with ASTM D-
882.
Clarity is measured in accordance with ASTM D-1746.
The terrr. " interpolymer" is used herein to indicate a copolymer, or a Cerpolymer, or a higher order polymer. That is, at least me other comonomer is polymerized with ethylene to make the interpolymer.
The ethylene/a-olefin interpolymer used in the films of the present invention is preferably a homogeneous linear or substantially linear ethylene/a-olefin interpolymer. By the term "homogeneous", it is meant that any comonomer is randomly distributed xithin a given interpolymer molecule and substantially all of the interpolymer molecules have the same ethylene/comcr-omer ratio within that interpolymer. The melting peak of homogeneous linear and substantially linear ethylene polymers, as obtained using differential scanning calorimetry, will broaden as the density decreases and/or as the number

average molecular weight decreases. However, unlike heterogeneous polymers, when a homogeneous polymer which has been prepared in a solution polymerization process has a melting peak greater than 115°C (such as is the case of polymers having a density greater than 0.940 g/cm^), it does not additionally have a distinct lower temperature melting peak.
In addition or in the alternative, the homogeneity of the constituents of the interpolymer may be described by the Crystallisation Temperature Breadth Index, CTBI. CTBI can be measured from data obtained from techniques known in the art, such as, for example, temperature rising elution fractionation (abbreviated herein as "TREF"), which is described, for example, in vrild et al. , Journal of Polymer Science, Poly. Phys. Ed., Vcl. 20, p. 441 (1982), in U.S. Patent 4,798,081 {Hazlitt eo al] . An example of how one obtains the CTBI for a given crystallization peak in the TREF experiment is shown in Figure 3. The calculation is applied only to individual, distinct crystallization peaks in the TREF analysis. The TREF data may he ceconvoluted prior to the calculation. The calculation consists of: (1) measuring the height of the crystallisait:n peak in question; then (2) measuring the width of the pea:-: at one-half the height. The value is reported in °C. The CTBI for the homogeneous ethylene/a-olefin interpolyir.ers useful in the invention is less than 18°C , preferably less than 15°C . A CTBI value of less than 10°C is
attainable.
The homogeneous ethylene interpolymer useful in the practice cf the invention will preferably have an M„ /M,, of from 1.5 to 3.5, more preferably from 1.7 to 3.0. It is noted that in the ezibodiment of the invention which comprises an in-reaction cr physical blend of two homogeneous polymers, the overall compcsition may have an M„/Mn of greater than 3.5, although the individual components will have an Mv,/Mn in the narrower ranee recited ?ihov(=

Linear ethylene interpolymers are interpolymers characterized as having an interpolymer backbone substituted with less than 0.01 long chain branches per 1000 carbons. Substantially linear ethylene interpolymers are interpolymers characterized as having an interpolymer backbone substituted with from O.Cl to 3 long chain branches per 1000 carbons. Due to the presence of such long chain branching, substantially linear ethylene interpolymers are further characterized as having a melt flow ratio {I10/I2) which may be varied independently of the polydispersity index, referred to alternatively as the molecular weight distribution or M„/Mn. This feature accords substantially linear ethylene polymers with a high degree of processability despite a narrow molecular weight distribution,
It 13 noted that the linear and substantially linear interpolymers useful in the invention differ from low density polyethylene prepared in a high pressure process. In one regard, whereas low density polyethylene is an ethylene homopolymer having a density of from 0.915 to 0.935 g/cm\ the homogeneous linear and substantially linear interpolymers useful in the invention require the presence of a comonomer to reduce the density to the range of from 0.900 to 0.935 g/cm^.
The long chain branches of substantially linear ethylene interpolymers have the same comonomer distribution as the interpol\—.er backbone and can be as long as about the same length as the length of the interpolymer backbone. In the preferred embodiment, wherein a substantially linear ethylene/a-olefin interpolymer is employed in the practice of the invention, such interpolymer will be more preferably be characterized as having an interpolymer backbone substituted with from O.Cl to 3 long chain branches per 1000 carbons.
Methods for determining the amount of long chain branching present, both qualitatively and quantitatively, are known in the art.

For qualitative methods for determining the presence of long chain branching, see, for example, U.S. Patent Nos. 5,272,236 and 5,278,272. As set forth therein, a gas extrusion rheometer (GE?.) may be used to determine the rheological processing index (PI), the critical shear rate at the onset of surface melt fracture, and the critical shear stress at the onset of gross melt fracture, which in turn indicate the presence or absence of long chain branching as set forth below.
The gas extrusion rheometer useful in the determination of rheological processing index (PI), the critical shear rate at the onset of surface melt fracture, and the critical shear stress at the onset of gross melt fracture, is described by M. Shida, R. N. Shroff, and L. V. Cancio in Polymer Engineering Science, Vol. 17, No. 11, p. 770 (1977), and in "Rheorr.eters for Molten Plastics" by John Dealy, published by Van Nostrand Reinhold Co. (1982) on pp. 97-99. GER experimen-s are performed at a temperature of 190°C, at nitrogen pressures between 250 and 5500 psig {between 1.72 and 37.9 MPa) using a 0.0754 mm diameter, 20:1 L/D die with an entrance angle of 180°.
For substantially linear ethylene interpolymers, the PI is the apparent viscosity (in kpoise) of a material measured by GER at an apparent shear stress of 2.15 x 10^ dynes/cm^ (0.215 MPa). Substantially linear ethylene interpolymers useful in the invencz-on will have a PI in the range of 0.01 Icpoise to 50 Jcpoise, preferably 15 kpoise or less. Substantially linear ethylene in.terpolymers have a PI which is less than or equal to 70 percent of the PI of a linear ethylene interpolymer (either a Ziegler pol-_.-merized polymer or a homogeneous linear ethylene interpolymer having the same comonomer or comonomers, and having an I;, M^/Mn, and density, each of which is within 10 percent of that of the substantially linear ethylene interpolymer.
An apparent shear stress versus apparent shear rate plot may be used to identify the melt fracture phenomena and to

quantify the ::ritical shear rate and critical shear stress of ethylene polyr-.ers. According to Ramamurthy, in the Journal of Rheology, 30(2", 1986, pages 337-357, above a certain critical flow rate, the observed extrudate irregularities may be broadly classified in-o two main types: surface melt fracture and gross melt fracture.
Surface melt fracture occurs under apparently steady flow conditions and ranges in detail from loss of specular film gloss to the ~ore severe form of "sharkskin." Herein, as determined using the above-described gas extrusion rheometer, the onset of surface melt fracture is characterized as the beginning of losing extrudate gloss at which the surface roughness of "he extrudate can only be detected by magnification at 40 times. The critical shear rate at the onset of surface melt fracture for a substantially linear ethylene interpolymer is at least 50 percent greater than the critical shear rate at the onset of surface melt fracture for a linear ethylene polymer having the same comonomer or comonomers and having an I2, 1%/Mr, and density within ten percent of that of the substantially linear ethylene polymer.
Gross melt fracture occurs at unsteady extrusion flow conditions and ranges from regular (alternating rough and smooth, helical, etc.) to random distortions. The critical shear stress at the onset of gross melt fracture of substantially linear ethylene interpolymers, especially those having a density greater than 0.910 g/cm^, is greater than 4 x 10^ dynes/cm- 0.4 MPa).
The presence of long chain branching may further be qualitatively determined by the Dow Rheology Index (DRI), which expresses a polymer"s "normalized relaxation time as the result of long chain branching." [See, S. Lai and G. W. Knight, ANTEC "93 Proceedings, INSITE™ Technology Polyolefins (SLEP)- New Rules in the Structure/Rheology Relationship of Ethylene a-Olefin Copol\—ers. New Orleans, La., May 1993. DRI values range from 0 for polymers which do not have any measurable long

chain branchir.g, such as Tafmer™ products available from Mitsui Petrochemical Industries and Exact™ products available from Exxon Chemical company) to 15, and are independent of melt index. In general, for low to medium pressure ethylene polymers, par-icular at lower densities, DRI provides improved correlations "o melt elasticity and high shear flowability relative to correlations of the same attempted with melt flow ratios. Substantially linear ethylene interpolymers will have a DRI of preferably at least 0.1, more preferably at least 0.5, and most preferably at least 0.8.
DRI may be calculated from the equation: DRI - (3.652879 * lol. 00649/Tio-l)/lO where TO is the characteristic relaxation time of the interpolymer =nd Tio is the zero shear viscosity of the interpolymer. Both TO and rjo are the "best fit" values to the Cross equaticr.:
n/Tlo ^ 1/{1 + (Y * to)^"") in which n is ^he power law index of the material, and r\ and y are the measured viscosity and shear rate, respectively. Baseline determination of viscosity and shear rate data are obtained using a Rheometric Mechanical Spectrometer (I?MS-800) under dynamic sweep mode from 0.1 to 100 radians/second at 160° C and a gas extrusion rheometer (GER) at extrusion pressures from 1,000 to 5,000 psi (6.89 to 34.5 MPa), which corresponds to a shear stress of from 0.086 to 0.43 MPa, using a 0.0754 mm diameter, 20:1 L/D die at 190""C. Specific material determinations may be performed from 140 to 190°C as required to accommodate melt index variations.
For quantitative methods for determining the presence of long chain branching, see, for example, U.S. Patent Nos. 5,272,236 and 5,278,272; Randall (Rev. Macromol. Chem. Phys., 029 (2&3), p. 285-297), which discusses the measurement of long chain branching using ^^C nuclear magnetic resonance spectroscopy, Zimm, G.H. and Stockmayer, W.H., J. Chem. Phys.,

17, 1301 1949); and Rudin, A., Modern Methods of Polymer Characterizat:Lon, John Wiley & Sons, New York (1991} pages 103-112, which discuss the use of gel permeation chromatography coupled wi:^h a low angle laser light scattering detector (GPC-LALLS) and gel permeation chromatography coupled with a differential viscometer detector (GPC-DV).
---. ".villem deGroot and P. Steve Chum, both of The Dow Chemical Company, at the October 4, 1994 conference of the Federation of Analytical Chemistry and Spectroscopy Society (FACSS) in St. Louis, Missouri, presented data demonstrating that GPC-DV is a useful technique for quantifying the presence of long chain branches in substantially linear ethylene polymers. Ir. particular, deGroot and Chum found that in substantially linear ethylene polymers, the measured values for long chain branches obtained by this method correlated well with the level of long chain branches measured using ^^C NMR.
Further, deGroot and Chum found that the presence of octane does not change the hydrodynamic volume of the polyethylene samples in solution and, as such, one can account for the molecular weight increase attributable to octene short chain branches by knowing the mole percent octene in the sample. By deconvoluting the contribution to molecular weight increase attributable to 1-octene short chain branches, deGroot and Chum shov.-ed that GPC-DV may be used to quantify the level of long chain branches in substantially linear ethylene/octene copolymers.
deGroot and Chum also showed that a plot of log(l2, melt index) as a function of log(GPC weight average molecular weight), as determined by GPC-DV, illustrates that the long chain branching aspects {but not the extent of long chain branching) of substantially linear ethylene polymers are comparable tc those of high pressure, highly branched low density polyethylene (LDPE) and are clearly distinct from heterogeneously branched ethylene polymers produced using Ziegler-type catalysts (such as linear low density polyethylene

and ultra low density polyethylene) as well as from homogeneous linear ethylene polymers (such as Tafmer™ products available from Mitsui Petrochemical Industries and Exact™ products available frcr. Exxon Chemical Company) . ■
Exer^.plary C3-C20 a-olefins used in the preparation of the ethylene interpolymers for use herein include propylene, isobutylene, 1-butene, 1-hexene, 4-methyl-l-pentene, 1-heptene, and 1-octene. Preferred C3-C20 a-olefins include 1-butene, 1-hexene, 4-methyl-l-pentene, 1-heptene, and 1-octene, more preferably 1-hexene and 1-octene. Exemplary cycloalkenes include cyclcpentene, cyclohexene, and cyclooctene. The dienes suitable as comonomers, particularly in the making of ethylene/ a-olefin/diene terpolymers, are typically non-conjugated dienes having from 6 to 15 carbon atoms. Representative examples of suitable non-conjugated dienes include:
(a) Straight chain acyclic dienes such as 1,4-hexadiene; 1,5-heptadier.e; and 1, 6-octadiene;
(b) Branched chain acyclic dienes such as 5-methyl-l,4-hexadiene; 3,7-dimethyl-1,6-octadiene; and 3 , 7-dimethy1-1,7-octadiene;
(c) Single ring alicyclic dienes such as 4-vinylcyclohexene; l-allyl-4-isopropylidene cyclohexane; 3-allylcyclopentene; 4-allylcv-clohexene; and l-isopropenyl-4-butenylc"_;"clohexene; and
(d) Multi-ring alicyclic fused and bridged ring dienes such as dicyclopentadiene; alkenyl-, alkylidene-, cycloalkenyl-, and cycl::alkylidene-substituted norbornenes, such as 5-methylene-2-norbornene; 5-methylene-6-methyl-2-norbornene; 5-methylene-6,6-dimethyl-2-norbornene; 5-propenyl-2-norbornene; 5-(3-cyclopentenyl)-2-norbornene; 5-ethylidene-2-norbornene; and 5-cyclohexylidene-2-norbornene.
One preferred conjugated diene is piperylene. The preferred dienes are selected from the group consisting of 1,4-hexadiene; di::yclopentadiene; 5 -ethylidene-2-norbornene; 5 -

methylene-2-n-rbornene; 7-methyl-l,6 octadiene; piperylene; and 4-vinylcyclohexene.
The linear or substantially linear ethylene interpolymer preferably is an interpolymer of ethylene with, at least one C3-C1; a-olefin comonomer.
While nor wishing to be bound by theory, it is believed that the compositions useful in the practice of the claimed invention owe zheir improved toughness and impact properties at least in part -o the presence of tie molecules. A tie chain is that portion rf the polyethylene chain which is expelled from the lEimellar crystal due to a short-chain branch imperfection. See, for instance, S. Krimm and T. C. Cheam, Faraday Discuss., Volume 68, pare 244 (1979); P. H. Geil, Polymer Single Crystals, published by Wiley, Inc., New York (1963); and P. J. Flory, J. ?^ rnem. Soc., Volume 84, page 2837 (1962). This expelled chain can then be reincorporated into another crystal, connecting the two crystals together. As the short chain branching increases, more tie chains form until the segments between shore-chain branches are not long enough to fold. In addition, cie chain concentration is proportional to molecular weight and car. be influenced by the type and amount of comonomer.
The effectiveness of an a-olefin to produce tie chains is proportional to its molecular size. For instance, 1-octene is a very efficient comonomer for promoting tie chain formation, as its hexyl group disrupts crystal formation more than the butyl or ethyl groups of hexene and butene comonomers, respectively. Accordingly, ethylene/octene polymer are believe to have higher levels of tie chains than copolymers of shorter chain comonomers, which is believed to lead to improved toughness. Hcj^ever, if the products are themselves produced in the gas phase or are targeted for competition with polymers produced in z"ne gas phase, one will typically utilize a C4-C6 a-olefin as che comonomer.

The homogeneously branched substantially linear ethylene polymer may be suitably prepared using a constrained geometry catalyst. Constrained geometry metal complexes and methods for their preparation are disclosed in U.S. Application Serial No. 545,403, filed July 3, 1990 (EP-A-416,815); U.S. Application Serial No. 702,475, filed May 20, 1991 [EP-A-514,828); as well as US-A-5,470,993, 5,374,696, 5,231,106, 5,055,438, 5,057,475, 5,096,867, 5,364,802, and 5,132,380. In US-A-5,721,185, certain borane derivatives of the foregoing constrained geometry catalysts are disclosed and a method for their preparation taught and claimed. In US-A-5,453,410, combinations of cationic constrained geometry catalysts with an alumoxane were disclosed as suitable olefin polymerization catalysts.
Exemplar-,-- constrained geometry metal complexes in which titanium is present in the +4 oxidation state include but are not limited "ZD the following:
(n-butylamido) dimethyl {r| -tetramethylcyclopentadienyl)
silanetitaniurr. {IV) dimethyl;
(n-butyl=mido) dimethyl {r] -tetramethylcyclopentadienyl) silanetitani"-iTTi (IV) dibenzyl;
(t-butylamido) dimethyl (i] -tetramethylcyclopentadienyl}
silanetitanium (IV) dimethyl;
(t-butylamido) dimethyl (ri -tetramethylcyclopentadienyl) silanetitaniiim (IV) dibenzyl;
(cyclodcdecylamido) dimethyl (.T\ -tetramethylcyclopentadienyl) silanetitanium (IV) dibenzyl;
(2,4, 5-trimethylanilido) dimethyl (TI -tetramethylcyclopentadienyl)silanetitanium (IV) dibenzyl;

(l-adamantyl-amido) dimethyl {r\ -tetramethylcyclopentadienyl) silanetitanium (IV) dibenzyl;
(t-butylamido)dimethyl {r\ -tetramethylcyclopentadienyl) silanetitaniuir. (IV) dimethyl;
(t-butylamido) dimethyl (ri -tetramethylcyclopentadienyl) silanetitaniur. (IV) dibenzyl;
(1-adamar.tylamido) dimethyl (r\ -tetramethylcyclopentadienyl)-silanetitanium (IV) dimethyl;
(n-butylamido) diisopropoxy {r\ -tetramethylcyclopentadienyl] silanetitaniurr. [IV) dimethyl;
[n-butyl=_-nido) diisopropoxy (ri -tetramethylcyclopentadienyl] silanetitaniurr. (IV) dibenzyl;
(cyclododecylamido) -diisopropoxy (r| -tetramethylcyclopentadienyl}-silanetitanium (IV) dimethyl;
(eye lode decylamido)diisopropoxy(Ti -tetramethylcyclopentadienyl)-silanetitanium [IV) dibenzyl;
(2,4, 6-trimethylanilido) diisopropoxy- (TI -tetramethylcyclopentadienyl) silanetitaniiim [IV) dimethyl;
(2,4, 6-trimethylanilido) diisopropoxy (ri -tetramethyl¬cyclopentadienyl )silanetitanium (IV) dibenzyl;
(eye lodo decylamido) dimethoxy ( T^ -tetramethylcyclopentadienyl) silanetitanium (IV) dimethyl;
(cyclododecylamido) -dimethoxy (rt -tetramethylcyclopentadienyl)silanetitanium (IV) dibenzyl;

(1-adainar.cylamido) diisopropoxy {r\ -tetratneth\-lcyclopentadienyl) si lane titanium (IV) dimethyl;
(l-adamar.nylamido) diisopropoxy (ti -tetramethylcyclopentadienyl)silanetItanium (IV) dibenzyl;
{n-butylainido)dimethoxy (TI -tetramethylcyclopentadienyl) silanetitaniura (IV) dimethyl;
(n-butylamido) dimethoxy (TI -tetramethylcyclopentadienyl) silanetitaniurr. (IV) dibenzyl;
(2,4, 6-crimethylanilido) dimethoxy (T) -tetramethylcyclopentadienyl)silanetitanium (IV) dimethyl;
(2,4, 5-trimethylanilido) dimethoxy (T| -tetramethylcy-lopentadienyl)silane-titanium (IV) dibenzyl;
[ 1-adamar.cylamido) dimethoxy (T] -tetramethylcyclo¬pentadienyl) silanetitanium (IV) dimethyl;
(1-adamanrylamido) dimethoxy (r| -tetramethylc\"clopentadienyl) silanetItanium [IV) dibenzyl;
(n-butyl=mido) -ethoxymethyl (T| -tetramethylc\-clopentadienyl) silanetItanium (IV) dimethyl;
(n-butyl=mido) ethoxymethyl {-q -tetramethylcyclopentadienyl) silanetitaniuTTL (IV) dibenzyl;
(cyclodcdecylamido) ethoxymethyl (r| -tetramethylcyclopentadienyl)silanetitanium (IV) dimethyl;
(eye lode decylamido) ethoxymethyl (r^ -tetramethylcyclopentadienvl) silanetitanium (IV) dibenzvl;

(2,4, 5-criraethylanilido) ethoxymethyl- (T] -tetramethylcyclopentadienyllsilanetitanium (IV) dimethyl;
[2,4, 6-crimethylanilido) ethoxymethyl (t] -tetramethylcyclopentadienyl)silanetitanium (IV) dibenzyl;
{cyclodcdecylamido ) dimethyl {T\ -tetramethylcyclopentadienyl) silane-titanium (IV) dimethyl;
(l-adamanTiylamido) -ethoxymethyl {r\ -tetramethylcyclopentadienyl) silanetitanium (IV) dimethyl; and
(l-adamar:::ylainido) ethoxymethyl (T| -tetramethylcyclopentadienyl) silanetitanium (IV) dibenzyl.
Exemplars- constrained geometry metal complexes in which titanium is present in the +3 oxidation state include but are not limited t= the following:
(n-butylsmido) dimethyl (T) -tetramethylcyclopentadienyl) silanetitani"JTT. (III) 2- (N, N-dimethylamino) benzyl;
(t-bucyl=mido)dimethyl^^ -tetramethylcyclopentadienyl)
silanetitaniuir. (Ill) 2- (N, N-dimethylamino) benzyl;
(eyelodeiecylamido) dimethyl {r\ -tetramethylcyclopentadienyl) silanetitanium (III) 2-{N,N-dimethylaminc benzyl;
(2,4, 6-trimethylanilido) dimethyl (i) -tetramethylcyclopentadienyl) silanetitanium (III) 2-(N,N-dimethylaminc benzyl;
(l-adamantylamido) dimethyl {r\ -tetramethylcyclopentadienyl)silanetitanium (III) 2-(N,N-dimethylaminc benzyl;

(t-bu::yl=mido) dimethyl [j] -tetramethylcyclopentadienyl) silanetitaniurr. (Ill) 2- (N,N-dimethylamino)benzyl,■
(n-butylamido) diisopropoxy (rj -tetramethylcyclopentadienyl) silanetitaniurr. (Ill) 2- (N,W-dimethylaraino)benzyl;
{cyclodcdecylamido) diisopropoxy (T) -tetramethylcyclopentadienyl) silanetitanium (III) 2-(N,N-dimethylarr.ino benzyl ;
(2,4, 5-trimethylanilido) diisopropoxy (TI -2-niethYlindenyl) silanetitaniurr. (Ill) 2- (N, N-dimethylamino) benzyl;
(l-adamar.tylamido) diisopropoxy (T| -tetramethylc\--lopentadienyl) silanetitanium (III) 2-(N,N-dimethylair.inc benzyl ,-
[n-bucylamido) dimethoxy {TI -tetramethylcyclopGntadienyl) silanetitaniurr, (III) 2- {N, N-dimethylamino) benzyl;
(eye lode decylamido) dimethoxy (T) -tetramethylc\-clopentadienyl) silanetitanium (III) 2-(N,N-dimethylarr.inc benzyl ;
(l-adamar,tylainido) dimethoxy (r] -tetramethylc\-::lopentadienyl) silane titanium (III) 2- (N,N-dimethylar.inc benzyl ;
(2,4, 5-trimethylanilido) dimethoxy (r| -tetrajnethylc"_.-clopentadienyl) silanetitaniiam (III) 2- (N,N-dimethylaminc benzyl;
(n-butylamido )ethoxymethyl{Ti -tetramethylcyclopentadienyl) silanetitaniun (III) 2-(N,N-dimethylamino)benzyl;

(cyclododecylamido) ethoxymethyl {ri -tetramethylcyclopentadienyl) silanetitanium (III) 2-(N,N-dimethylamino)benzyl;
(2,4, 6-trimethylanilido) ethoxymethyl (r| -tetramethylcyclopentadienyl) silanetitanium (III) 2-{N,N-dimethylamino)benzyl; and
(1-adamantylamido) ethoxymethyl {r\ -tetramethylcyclopentadienyl) silanetitanium (III) 2-{N,N-dimethylamino)benzyl.
Exemplar^-" constrained geometry metal complexes in which titanium is present in the +2 oxidation state include but are not limited to the following:
(n-butylamido) -dimethyl- (T] -tetramethylcyclopentadienyl) silanetitaniu.-r> (II) 1, 4-diphenyl-l, 3-butadiene;
(n-butylamido) dimethyl (ri -tetramethylcyclopentadienyl) silanetitaniuiTi [II) 1, 3-pentadiene;
{t-butylamido) dimethyl (rj -tetramethylcyclopentadienyl) silanetitaniurr. (II) 1, 4-diphenyl-l, 3-butadiene;
(t-butyiamido) dimethyl (T] -tetramethylcyclopentadienyl) silanetitaniuir. (11) I, 3-pentadiene;
[cyclododecylamido) dimethyl {T\ -tetramethylcyclopentadienyl) silanetItanium (II) 1,4-diphenyl-1,3-butadiene;
(cyclododecylamido) dimethyl (TI -tetramethylcyclopentadienyl) silanetitanium (II) 1,3-pentadiene;

(2,4, 5-trimethylanilido)dimethyl ix] -tetramethylcy::lopentadienyl) silaneti tanium (II) 1, 4-diphenyl-1,3-butadiene r
(2,4, 6-trimethylanilido) dimethyl (r| -tetramethylcyclopentadienyl) silanetitanium (II) 1,3-pentadiene;
(2,4, 5-triraethylanilido)dimethyl (ri -tetramethylcy-lopentadienyl) silanetitanium (IV) dimethyl;
(l-adamantylamido) dimethyl (r| -tetramethylcyclopentadienyl) silane-titani-jjn {II) 1, 4-diphenyl-1, 3-butadiene;
{l-adaraar.tylamido)dimethyl (T| -tetramethylcyclopentadienyl) silanetitaniur-. (II) 1,3-pentadiene;
(t-butyl ami do) dimethyl {TI -tetramethylcyclopentadienyl) silanetitaniu-- (II) 1, 4-diphenyl-l, 3-butadiene;
{t-butyl=.-nido) dimethyl (TI -tetramethylcyclopentadienyl) silanetitaniurr. (II) 1,3-pentadiene;
(n-butylamide) diisopropoxy {ri -tetramethylcyclopentadienyl)
silanetitani--:rr, (II) 1, 4-diphenyl-l, 3-butadiene;
{n-butyl=jnido)diisopropoxy (n -tetramethylcyclopentadienyl) silanetitaniurr. (II) 1, 3-pentadiene;
(cyciodcdecylamido) -diisopropoxy (TI -tetramethylcyclopentadienyl) silanetitanium (II) 1,4-diphenyl-1,3-butadiene:
(cyciodcdecylamido) diisopropoxy {T| -tetramethylc^-clopentadienyl) silaneti tanium (II) 1,3-pentadiene;
(2,4, 5--rimethylanilido) diisopropoxy (TI -2-methyl-indenyl) silanetitaniuin (II) 1, 4-diphenyl-l, 3-butadiene;

[2,4, 5-trimethylanilido) -diisopropoxy [T] -tetramethylcyclopentadienyl) silanetitanium (11) 1,3-pentadiene;
[l-adamar-cylamido) diisopropoxy (TJ -tetramethylcyclopentadienyl) silanetitanium (II) 1,4-diphenyl-1,3-butadiene:
[l-adamar.tylamido) diisopropoxy (T) -tetramethylcyclopentadienyl) silanetitaniiun (II) 1,3-pentadiene;
[n-butyla:nido)dimethoxy{TI -tetramethylcyclopentadienyl) silanetitaniurr. (II) 1, 4-diphenyl-l, 3-butadiene,■
(n-butyl=jaido)dimethoxy{r| -tetramethylcyclopentadienyl) silanetitaniuTT. (II) 1, 3-pentadiene;
(cyclodciecylamido) dimethoxy {TJ -tetramethylcyclopentadienyl) silanetitanium (II) 1,4-diphenyl-1,3-butadiene;
(eyelodedecylamido) dimethoxy (ri -tetramethylc\-zlopentadienyl} silane titanium (II) 1,3-pentadiene;
(2,4, 6-trimethylanilido) dimethoxy (T) -tetramethylcyclopentadienyl) silanetitanium (II) 1,4-diphenyl-1,3-butadiene:
(2,4, 6-trimethylanilido) dimethoxy (ri -tetramethylc\-clopentadienyl) silanetitanitun (II) 1,3-pentadiene;
(1-adamarLtyl-amido) dimethoxy (T] -tetramethylcyclopentadienyl) silanetitanium (11) 1,4-diphenyl-1,3-butadiene:

(l-adamar-.rylamido) dimethoxy (r) -tetramethylcyclopentadienyl) silanetItanium (II) 1,3-pentadiene;
(n-bu-yl=jTiido) ethoxymethyl (rj -tetramethylcyclopentadienyl;
silanetitaniurr. (II) 1, 4-diphenyl-1, 3-butadiene;
(n-bucylamido) ethoxymethyl (r| -tetramethylcyclopentadienyl! silanetitaniurr. (II) 1,3-pentadiene;
(cyclodcdecylamido) ethoxymethyl {r\ -tetramethylcyclopentadienyl) silanetItanium (II) 1,4-diphenyl-1,3-butadiene:
(cyclodcdecylamido) ethoxymethyl (r| -tetramethylcyclopentadienyl) silanetItanium (II) 1,3-pentadiene;
(2,4, 5-trimethylanilido) ethoxymethyl (r| -tetramethylcyclopentadienyl) silanetitanium (II) 1,4-diphenyl-1,3-butadiene:
(2,4, 5-criiiiethylanilidQ) ethoxymethyl (r) -tetramethylc\-clopentadienyl) si lane titanium (II) 1,3-pentadiene;
(1-adamancylamido) ethoxymethyl (r| -tetramethylcyclopentadienyl) silanetItanium (II) 1,4-diphenyl-1,3-butadiene r and
(l-adamanrylamido) ethoxymethyl {ti -tetramethylcyclopentadienyl) silanetItanium (II) 1,3-pentadiene.
The complexes can be prepared by use of well known synthetic techniques. The reactions are conducted in a suitable noninterfering solvent at a temperature from -100 to 300 ^C, preferably from -78 to 100 °C, most preferably from 0 to 50 °C. A reducing agent may be used to cause the metal to

be reduced frrm a higher to a lower oxidation state. Examples of suitable reducing agents are alkali metals, alkaline earth metals, aluminum and zinc, alloys of alkali metals or alkaline earth metals such as sodium/mercury amalgam and sodium/potassi-om alloy, sodium naphthalenide, potassium graphite, lithium alkyls, lithium or potassium alkadienyls, and Grignard reagents.
Suitable reaction media for the formation of the complexes include aliphatic and aromatic hydrocarbons, ethers, and cyclic ethers, particularly branched-chain hydrocarbons such as isobutane, bu-ane, pentane, hexane, heptane, octane, and mixtures thereof; cyclic and alicyclic hydrocarbons such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof; aromatic and hydrocarbyl-substituted aromatic compounds such as benzene, toluene, and i^r/lene, C1-4 dialkyl ethers, Ci_4 dialkyl ether derivatives cz (poly)alkylene glycols, and tetrahydrofuran. Mixtures of "he foregoing are also suitable.
Suitable activating cocatalysts and activating techniques have been previously taught with respect to different metal complexes in the following references: EP-A-277,003, US-A-5,153,157, US-A-5,064,802, EP-A-468,651 (equivalent to U. S. Serial No. 0" 547,718), EP-A-520,732 {equivalent to U- S. Serial No. 0" 376,268), WO 95/00683 (equivalent to U.S. Serial No. 08/82,201 , WO 97/35893 (equivalent to U.S. Serial No. 08/818,530), and EP-A-520,732 (equivalent to U. S. Serial No. 07/884,966 filed May 1, 1992).
Suitable activating cocatalysts for use herein include perfluorinated tri(aryl)boron compounds, and most especially tris(pentafluorophenyl)borane; nonpolymeric, compatible, noncoordinatir.g, ion forming compounds (including the use of such compounds under oxidizing conditions), especially the use of ammoni"ora- phosphonium-, oxonium-, carbonium-, silylium- or sulfonium- salts of compatible, noncoordinating anions, and

ferrocenium salts of compatible, noncoordinating anions. Suitable activating techniques include the use of bulk electrolysis explained in more detail hereinafter). A combination of the foregoing activating cocatalysts and techniques mai-- be employed as well.
Illustrative, but not limiting, examples of boron compounds which may be used as an activating cocatalysts are: tri-substituted ammonium salts such as: trimethylammonium tetrakis(pentafluorophenyl) borate; triethylammonium tetrakis{pentafluorophenyl) borate; tripropylammonium tetrakis{pentafluorophenyl) borate; tri(n-butyl)ammonium tetrakis{pentafluorophenyl) borate; tri{sec-butyl)ammonium tetrakis[pentafluoro-phenyl) borate; N,N-dimethylanilinium tetrakis(pentafluorophenyl) borate; N,N-dimethylanilinium n-butyltris(pentafluorophenyl) borate; N,N-dimethylanilinium benzyltris(pentafluorophenyl) borate; N,N-dimethylanilinium tetrakis(4-{t-butyldimethylsilyl)-2, 3, 5, 6-tetrafluorophenyl) borate; N,N-dimethylanilinium tetrakis(4-{triisopropylsilyl}-2, 3, 5, 6-tetrafluorophenyl) borate; N,N-dimethylanilinium pentafluorophenoxytris (pentafluorophenyl) borate; N,N-diethylanilir.i"jm tetrakis (pentaf luorophenyl) borate; N,N-dimethyl-2,4.f-trimethylanilinium tetrakis(pentafluorophenyl) borate; trime-hylammonium tetrakis(2,3,4,5-tetrafluorophenyl) borate; triethylammonium tetrakis(2,3,4,6-tetrafluorophenyl) borate; tripropylammonium tetrakis(2,3,4,6-tetrafluorophenyl) borate; tri(n-butyl)ammonium tetrakis(2,3,4,6-tetrafluorophenyl) borate; dimethyl(t-butyl)ammonium tetrakis(2,3,4,6-tetrafluorophenyl) borate; N,N-dimethylanilir.ium tetrakis (2, 3,4, 6-tetraf luorophenyl) borate; N,N-diethylanilinium tetrakis(2,3,4,6-tetrafluorophenyl) borate; and N,N-dimethyl-2,4,6-trimethylanilinium tetrakis(2,3,4,6-tetrafluorophenyl) borate;
disubstituted ammonium salts such as: di-(isopropyl) ammonium tetrakis{pentafluorophenyl) borate; and dicyclohexylammonium tetrakis(pentafluorophenyl) borate;

trisubst^-uted phosphonium salts such as: triphenylphosphonium tetrakis(pentafluorophenyl) borate; tri(o-tolyl)phosphonium tetrakis{pentafluorophenyl) borate; and tri(2,6-dimethylphenyl)phosphonium tetrakis {pentafluorophenyl) borate;
disubstizuted oxonium salts such as: diphenyloxohium tetrakis (pentaf luorophenyl) borate; di (o-tolyl) oxoniuin tetrakis(pentafluorophenyl) borate; and di(2,6-dimethyl-phenyl) oxoniurr. tetrakis (pentaf luorophenyl} borate; and
disubsti-uted sulfonium salts such as: diphenylsulfonium tetrakis(pentafluorophenyl) borate; di(o-tolyl)sulfonium tetrakis{pentafluorophenyl) borate; and bis(2,6-dimethylptienyl: sulfonium tetrakis (pentaf luorophenyl) borate.
Alternate preferred cocatalysts may be represented by the following general formula:
(L*-H)d" (A")^" wherein:
L* is a neutral Lewis base;
(L*-H)"*" 15 a Bronsted acid;
A""^" is a noncoordinating, compatible anion having a charge of d-, and
d is an _nteger from 1 to 3.
More preferably A"*^" corresponds to the formula: [M*Q4]";
wherein:
M* is bciron or aluminum in the +3 formal oxidation state; and
Q independently each occurrence is selected from hydride, dialkylamido, halide, hydrocarbyl, halohydrocarbyl, halocarbyl.

hydrocarbyloxide, hydrocarbyloxy substituted-hydrocar^by 1, organometal substituted-hydrocarbyl, organometalloid substituted-hydrocarbyl, halohydrocarbyloxy, halohydrocarbyloxy substituted hydrocarbyl, halocarbyl- substituted hydrocarbyl, and halo- substituted silylhydrocarbyl radicals (including perhalogenated hydrocarbyl- perhalogenated hydrocarbyloxy- and perhalogenated silylhydrocarbyl radicals), said Q having up to 20 carbons wizh the proviso that in not more than one occurrence is Q halide. Examples of suitable hydrocarbyloxide Q groups are disclosed in U. S. Patent 5,296,433.
In a more preferred embodiment, d is one, that is, the counter ion has a single negative charge and is A"". Activating cccatalysts comprising boron which are particularly useful may be represented by the following general formula:
[L*-K)"[2Q4)";
wherein:
L* is as previously defined;
B is boron in a formal oxidation state of 3; and
Q is a hydrocarbyl-, hydrocarbyloxy-, fluorinated hydrocarbyl-, fluorinated hydrocarbyloxy-, or fluorinated silylhydrocarbyl- group of up to 20 nonhydrogen atoms, with the proviso that in not more than one occasion is Q hydrocarbyl.
Most preferably, Q is each occurrence a fluorinated aryl group, especially, a pentafluorophenyl group.
Illustrarive, but not limiting, examples of boron compounds which may be used as an activating cocatalyst are tri-substituced ammonium salts such as:
trimethylammcnium tetraphenylborate, methyldioctadecylammonium tetraphenylborate, triethylammonium tetraphenylborate,

tripropylarjnor.ium tetraphenylborate,
tri(n-butyl)amnonium tetraphenylborate,
methyltetradecyloctadecylaininoniuin tetraphenylborate,
N,N-dimethylar-iliniiim tetraphenylborate,
N,lSl-diethylanilinium tetraphenylborate,
N,N-dimethyl (2,4, 6-trimethylaniliniuin) tetraphenylborate,
trimethylammor.ium tetrakis (pentafluorophenyl)borate,
methylditecradecylammoniuin tetrakis (pentafluorophenyl) borate,
inethyldioc::adecylaminonium tetrakis (pentaf luorophenyl) borate,
triethylammonium tetrakis(pentafluorophenyl)borate,
tripropylainmonium tetrakis (pentafluorophenyl) borate,
tri (n-butyl) arrjnonium tetrakis {pentaf luorophenyl) borate ,
tri(sec-bucyl.ammonium tetrakis(pentafluorophenyl)borate,
N, N-dimethylar.ilinium tetrakis (pentafluorophenyl) borate,
N,N-diethylanilinium tetrakis(pentafluorophenyl)borate,
N,N-dimethyl(2,4,6-trimethylanilinium)
tetrakis(pentafluorophenyl)borate.
trimethylammonium tetrakis(2,3,4,6-tetrafluorophenyl)borate,
trie thy lammoni-om tetrakis (2,3,4, 6-tetraf luorophenyl) borate,
tripropylammonium tetrakis(2,3,4,6-tetrafluorophenyl)borate,
tri (n-butyl) az-jnonium tetrakis (2,3,4, 6-tetraf luorophenyl) borate,
dimethyl(t-bu^yl)ammonium tetrakis(2,3,4,5-
tetrafluorophenyl)borate, N,N-dimethylanilinium
tetrakis ( 2 , 3 , ri, 6-tetrafluorophenyl) borate,
N,N-diethylan^linium tetrakis(2,3,4,6-tetrafluorophenyl)borate,
and N,N-dimenhyl-(2,4,6-trimethylanilinium) tetrakis-(2,3,4,6-
tetrafluorophenyl)borate.
Dialkyl ammonium salts such as: dioctadecylair:zvonium tetrakis (pentaf luorophenyl)borate , ditetradecylarjnonium tetrakis(pentafluorophenyl)borate, and dicyclohexylarrjnonium tetrakis (pentaf luorophenyl) borate .
Tri-subsiituted phosphonium salts such as: triphenylpbosphonium tetrakis(pentafluorophenyl)borate, methyldioccacGcylphosphonium tetrakis(pentafluorophenyl)borate.

and tri(2,5-dimethylphenyl)phosphoniumtetrakis-(pentaf luorophenyl ) borate.
Preferred are tetrakis(pentafluorophenyl)borate salts of long chain alkyl mono- and disubstituted ammonium complexes, especially C--C20 alkyl ammonium complexes, especially methyldi(octadecyl)ammonium tetrakis(pentafluorophenyl)borate and methyldi(tetradecyl)-ammonium
tetrakis{pentafluorophenyDborate, or mixtures including the same Such mixtures include protonated ammonium cations derived from amines comprising two C14, Cis or Cia alkyl groups and one methyl group. Such amines are available from Witco Corp., under the trade name Kemamine™ T9701, and from Akzo-Nobel under the trade nair.e Armeen™ M2HT.
Another suitable ammonium salt, especially for use in heterogeneous catalyst systems, is formed upon reaction of a organometal compound, especially a tri(C^-galkyl)aluminum
compound wit"r. an ammonium salt of a hydroxyaryltris {f luoroaryl) borate compour.d. The resulting compound is an organometalox^"aryltris(fluoroaryl)borate compound which is generally insrluble in aliphatic liquids. Typically, such compounds are advantageously precipitated on support materials, such as silica, alumina or trialkylaluminum passivated silica, to form a supported cocatalyst mixture. Examples of suitable compounds include the reaction product of a tri (C]__g
alkyl) aluminurr. compound with the ammonium salt of hydroxyaryltris(aryl)borate.
Suitable hydroxyaryltris(aryl)-borates include the ammonium salts, especially the forgoing long chain alkyl ammonium salts of:
{4-dimethylaluminumoxy-1-phenyl)tris(pentafluorophenyl}borate, (4-dimethyla^-.:minumoxy-3 , 5-di {trimethylsilyl) -1-phenyl)tris(pentafluorophenyl)borate, (4-dimethylal--Lminumoxy-3, 5-di (t-butyl) -1-

phenyl)tris(pentafluorophenyl)borate,
(4-dimethylal"-iminumoxy-l-benzyl) tris (pentaf luorophenyl) borate, (4-dimethylal-.ii:iinumoxy-3-methyl-l-phenyl)tris(pentafluorophenyl)borate, (4-dirrethylal-,ii:iinuraoxy-tetraf luoro-l-phenyl)tris(pentafluorophenyl)borate, (5-dimethylal"-L::iinumoxy-2-naphthyl]tris pentafluorophenyl)borate, 4- (4-dimethylaluininumoxy-l-
phenyl)phenylzris(pentafluorophenyl)borate, 4- (2- (4- {dimGzhylaluininumoxyphenyllpropane-2-yl)phenyloxy)-ris(pentafluorophenyl}borate,
(4-diethylaluminumoxy-l-phenyl)tris(pentafluorophenyl)borate, (4-diethylalurr.inuinoxy-3 , 5-di (trimethylsilyl) -1-phenyl)tris(pentafluorophenyl)borate, (4-diethylalu:r.inumoxy-3 , 5-di (t-butyl) -1-phenyl)tris(pentafluorophenyl)borate,
[4-diethylaluz-.inumoxy-l-ben^yl) tris (pentaf luorophenyl) borate, ( 4-diethylalu=-.inumoxy-3-methyl-1-phenyl) tris [pentaf luorophefiyl) borate , (4-diethylaiui:-:Lnumoxy-tetraf lucre-1-phenyl)tris[pentafluorophenyl)borate,
(5-diethylalur-.inuinoxy-2-naphthyl) tris (pentaf luorophenyl) borate, 4- (4-diethylal"jjninumoxy-l-
phenyl)phenyl-ris(pentafluorophenyl)borate, 4-(2-(4-(diethylaluminumoxyphenyl)propane-2-yl)phenyloxy)zris(pentafluorophenyl)borate, (4-diisopropylaluminumoxy-l-phenyl)tris(pentafluorophenyl)borate, {4-diisopropylalurainumoxy-3,5-di[trimethylsilyl)-1-phenyl) tris (pentaf luorophenyDborate, (4-diisopropylaluniinumoxy~3 , 5-di (t-butyl) -1-phenyl)tris(pentafluorophenyl)borate, (4-diisopropylaluminuinoxy-l-benzyl)tris(pentafluorophenyl)borate,

(4-diisopropYialuminum.oxy-3-methyl-l-phenyl)tris(pentafluorophenyl)borate,
(4-"diisopropylaluminuinoxy-tetraf luoro-1-phenyl)tris(pentafluorophenyl)borate,
(5-diisopropyialuminuinoxy-2-naphthyl)tris.pentafluorophenyl)borate, 4-(4-diisoprcpylaluminumoxy-l-
phenyl)phenyltris(pentafluorophenyl)borate, and 4- {2- (4- (diisopropylaliiminumoxyphenyl)propane-2-yl)phenyloxy)tris(pentafluorophenyl)borate.
An especially preferred ammonium compound is methylditetradecylammonium (4-diethylaluminumoxy-l-phenyl ) tris(pentafluorophenyl}borate, methyldihexadecylammonium (4-diethylal-.iminumoxy-l -phenyl) tris {pentaf luorophenyl} borate, methyldioctadecyl-ammonium (4-diethylaluminumoxy-l-phenyl ) tris (pentaf luorophenyl) borate, and mixtures thereof. The foregoing complexes are disclosed in WO96/28480, which is equivalent tc USSN 08/610,647, filed March 4, 1996, and in USSN 08/768,518, filed December 18, 1996.
Alumoxanes, especially methylalumoxane or triisobutylal-.iminum modified methylalumoxane are also suitable activators and may be used for activating the present metal complexes.
The rr.olar ratio of metal complex: activating cocatalyst employed preferably ranges from 1 : 1000 to 2 ; 1, more preferably from 1 : 5 to 1.5 : 1, most preferably from 1 : 2 to 1:1. In the preferred case in which a metal complex is activated by trispentafluorophenylborane and triisobutylal--iminum modified methylalumoxane, the titanium:borcn:aluminum molar ratio is typically from 1 : 10 : 50 to 1 : 0.5 : 0.1, most typically from 1:3:5. A most preferred activating cocatalyst is trispentafluorophynylborane (FAB), optionally in combination with an alumoxane, the molar

ratio of metal complex:FAB;alumoxane being from. 1:1:5 to 1:10:50.
A suppor-, especially silica, alumina, or a polymer {especially poly{tetrafluoroethylene) or a polyolefin) may be employed, and desirably is employed when the catalysts are used in a gas phase or slurry polymerization process. The support is preferably employed in an amount to provide a weight ratio of catalyst (based on metal):support from 1:100,000 to 1:10, more preferably from 1:50,000 to 1:20, and most preferably from 1:10,000 to 1:30.
At all times, the individual ingredients as well as the recovered catalyst components must be protected from oxygen and moisture. Therefore, the catalyst components and catalysts must be prepared and recovered in an oxygen and moisture free atmosphere. Preferably, therefore, the reactions are performed in the presence of an dry, inert gas such as, for example, nitrogen.
The pol\Tr.erization will preferably be conducted in a continuous polymerization process. In a continuous process, ethylene, corr.cnomer, optionally solvent and diene, are continuously supplied to the reaction zone and polymer product continuously removed therefrom.
In general, the first polymer may be polymerized at conditions fcr Ziegler-Natta or Kaminsky-Sinn type polymerizaticn reactions, that is, reactor pressures ranging from atmospheric to 35er0 atmospheres (355 MPa) . The reactor temperature should be greater than SO^C, typically from 100°C to 250°C, and preferably from 100""C to 150°C, with temperatures at the higher end of the range, temperatures greater than 100°C favoring the formation of lower molecular weight polymers.
In conjunction with the reactor temperature, the hydrogen:ethylene molar ratio influences the molecular weight of the polymer, with greater hydrogen levels leading to lower

molecular v/eight polymers. The molar range of hydrogen: ethylene will typically range from 0.0:1 to 2.5:1.
Generall\- the polymerization process is carried out at a pressure of from 10 to 1000 psi (70 to 7000 kPa), most preferably fr-m 400 to 800 psi (280 to 5500 kPa). The polymerizacicn is generally conducted at a temperature of from 80 to 250=C, preferably from 90 to llO^C. and most preferably from greater zhan 95°C to 140°C.
In most polymerization reactions the molar ratio of catalyst :pol\-:r.erizable compounds employed is from 10-12:1 to 10-1:1, more preferably from 10-9:1 to 10-5:1. Solution polymerizaricn conditions utilize a solvent for the respective components of the reaction. Preferred solvents include mineral oils and the various hydrocarbons which are liquid at reaction temperatures. Illustrative examples of useful solvents include alkanes such as pentane, iso-pentane, hexane, heptane, octane and nonane, as well as mixtures of allcanes including kerosene and Isopar-HP". available from Exxon Chemicals Inc. ; cycloalkanes such as cyclopentane and cyclohexane; and aromatics such as benzene, toluene, xylenes, ethylbenzene and diethylbenzene.
The solvent will be present in an amount sufficient to prevent phase separation in the reactor. As the solvent functions zo absorb heat, less solvent leads to a less adiabatic rea~ror. The solvent:ethylene ratio (weight basis) in the feed v;ill typically be from 2.5:1 to 12:1, beyond which point catalys- efficiency suffers. The most typical solvent:ethylene ratio (weight basis) in the feed is in the range of from 2.5:1 to 6:1.
The erh\-lene/a-olefin interpolymer may alternatively be prepared in a gas phase polymerization process, using the catalysts as described above as supported in an inert support, such as silica. The ethylene/a-olefin interpolymer may further be made in a slurry polymerization process, using the catalysts as described above as supported in an inert support.

such as silica. As a practical limitation, slurry polymerizaCicr.s take place in liquid diluents in which the polymer product is substantially insoluble. Preferably, the diluent for slurry polymerization is one or more hydrocarbons with less thar. 5 carbon atoms. If desired, saturated hydrocarbons such as ethane, propane or butane may be used in whole or part as the diluent. Likewise the a-olefin monomer or a mixture of different a-olefin monomers may be used in whole or part as the diluent. Most preferably the diluent comprises in at least rr.a j or part the a-olefin monomer or monomers to be polymerized.
The pol\—.ers may be produced via a continuous (as opposed to a batch) crntrolled polymerization process using at least one reactor, but can also be produced using multiple reactors (for example, using a multiple reactor configuration as described in V.S. Patent No. 3,914,342 (Mitchell)), with the second ethylene polymer polymerized in at least one other reactor. The multiple reactors can be operated in series or in parallel, witr. at least one constrained geometry catalyst employed in at least one of the reactors at a polymerization temperature ar.d pressure sufficient to produce the ethylene polymers having the desired properties.
The mel- index of the polymer compositions useful in the present inven-ion will be chosen on the basis of the targeted end use appliration. For instance, polymer compositions having a melt index -f at least 2 grams/10 minutes, preferably at least 3 grams 10 minutes; and preferably no more than 8 grams/10 minutes, preferably no more than 7 grams/10 minutes, will be usefully employed in general purpose blown film applications.
Likewise, polymer compositions having a melt index of less than 1 gram/i: minutes, preferably less than 0.75 gram/10 minutes, will be usefully employed in heavy duty bags and other high strength film applications.

Those films of the invention which are characterized as higher clarity films, will preferably be characterized as having a haze of less than 12 percent, preferably less than 11 percent, more preferably less than 10 percent. For instance, exemplary of -he polymer compositions which lead to the
production of such most preferred films, are the ethylene/a-olefin interpoiymers of the invention having a melt index of less than 1 gram/10 minutes, preferably less than 0.7 5 gram/10 minutes, and having an I10/I2 of at least 10, preferably at least 12.
The compcsitions of the invention may optionally be melt-blended with z-her thermoplastic polymers, such as low density polyethylene. Linear low density polyethylene, high density polyethylene, ethylene vinyl acetate, ethylene vinyl alcohol, polypropylene, polycarbonate, and ethyiene/styrene interpoiymers, provided that the formation of such a blend does not deleteriously interfere with the desired performance. Typically, such an additional thermoplastic polymer will be provided to the blend in an amount offrom 1 to 30 weight percent, preferably from 1 to 15 weight percent.
Certain ;f the compositions of the invention will be prepared in a dual reactor configuration in accordance with techniques knc^/m in the art. For instance, dual reactor systems are disclosed and claimed in USSN 08/858664 {EP 619,827) and "3SJ:i 03/747,419 (?CT Publication WO 94/17112).

Accordingly, the present invention provides a film having at least one layer comprising a homogeneous interpolymer of ethylene and at least one comonomer selected from the group consisting of C3-C20 a-olefins, dienes, and cycloajkenes, wherein the interpolymer is characterized as having: a) a density of from 0.910 to 0.930 g/cm^ as measured according to the procedures of ASTM D792; b) a melt index (I2) of from 0.05 to 10 g/10 minutes, as measured according to procedures of ASTM D-1238, Condition 190""C/2.16 Kg formerly known as Condition E; c) an ho/li of from 9 to 20, with I]o measured according to the procedures of ASTM D-1238, Condition 190°C/\Q Kg formerly known as Condition N; d) a molecular weight distribution, Mn/Mn, of from 2.1 to 5 as measured using narrow molecular weight distribution polystyrene standards in conjunction with their elution volumes; and e) wherein the interpolymer is fiirther characterized as having a single crystallization peak between 45""C and 98""C and having a Crystallization Temperature Breadth hidex (CTBI) of less than IS^C, as determined by temperature rising elution fractionation (TRBF).
Examples
High Processing Polymers having an h Greater than 2 g/10 minutes
The polymers of Comparative Examples A and B were commercially available low density polyethylene.
The polymers of Comparative Examples C, D and E, were substantially linear ethylene/a-olefin copolymers having an IK/II of less than 9 and an M^/M^ of from 2.175 to 2.543.
The polymers of Examples 1-3 were substantially linear ethylene/butene
compositions prepared in a parallel dual reactor polymerization process as described
in USSN 08/858664

(EP 619,827). In each example, a catalyst comprising (t-butylamidojdirr.ethyDri ^-tetramethylcyclopentadienyl) silanetitaniun (II) 1,3-pentadiene catalyst, activated with trispentafluorophenylborane and triisopropylaluminxim modified methylaluir.oxar.e (MMAO, available from Akzo Chemical) was employed. In each example, the reactor conditions were selected s-^ch as to produce a product having a uniform density (that is, each reactor was run such as to give a product having the same density), but which is bimodal in terms of molecular weight. In Table One, Parts I and II, the properties for the products of the first and second reactors are indicated by Rl and R2, respectively.
For instance, in the case of Example 3, the following reactor condi-ions may be employed:
Table One: Part I

Rl R2
Solvent Feed Kg/h) 15.0 27.0
Ethylene Feed (Kg/h) 2.2 2.95
Hydrogen Feed (SCCM) 0.3 61
Butene Feed :"%g/h) 0.38 0.24
Ethylene Conv. % 80 90
Feed Temp C) 15 15
Reactor Tenp C) 110 12 0
Catalyst Flow ( kg/hj 9.13 X 10"" 4.6 X 10"°
Primary
Co-catalyst Flow (kg/h) 2.74 X 10"° 1.38 X 10"="
Secondary Co-catalyst Flow (kg/h) 4.6 X 10"" 2.3 X 10""
The pol\-ner of Example 4 was a substantially linear ethylene/1-butene copolymer prepared in a single solution polymerizatic- reactor. The polymer of Example 4 was prepared in accordance with the procedures of U.S. Patent No. 5,272,236 and U.S. Patent No. 5,278,272, utilizing a (t-butylainido)di-ethyl)r] ^-tetraitiethylcyclopentadienyl) silanetitaniun (II) 1,3-pentadiene catalyst, activated with trispentaflucrophenylborane and modified methylalumoxane.

The properties of the polymers of Comparative Examples A -E and of Examples 1-4 are set forth in the following Table One, Part II.

Table One, Part II

Comparative Example A Comparative
Example B Comparative Example C Comparative Example D Comparative Example E Example 1 Example 2 Example 3 Example 4
Process Comonomer Autoclave Tubular Single Rniirtnr Octene Single
Roaclor Butane Single
Rnnctor Butene Dual Rnaclnr Butene Dual Roadnr Butene Dual Ronctor Butene Single Ronclnr
Butene
Density (q/cc) 0.9210 0.9198 0.9183 0.9165 0.9145 0.9209 0.9160 0.9150 0.918
l2(q/10 min) 5.0 5.0 6.2 9.6 7.5 5.0 2.8 5.4 5.5
Uh 11.7 12.5 8.8 7.6 7.7 9.4 10.0 11.7 9.2
R1 l?(q/10min) - - - - - 0.3 0.8 0.1 -
R2l2(q/10min) - - - - - 60 100 50 -
R1 l,o/l?(q/10min) - - - - - 8.5 8.0 9.0 -
R2l,o/Uq/10min) - - - - - 7.0 7.0 7.0 -
Reactor Split - - - - - 35 80 35 -
Melting Temperature ("C) 110.9 108.0 113.1 106.0 104.8 108.1 110.8 102.7 -
Crvstallization Temp ("C) 97.8 94.3 98.2 89.8 90.0 93.6 96.8 68.0 -
Crvstallinitv (%) 48.5 48.9 50.2 44.8 45,6 47.0 44.5 41.7 -
Weight Average Molecular Weiqht (Mw) 66400 87900 55700 52300 55700 62400 67000 68700 56600
Number Average Molecular Weiqht (Mn) 15300 15600 21900 22900 25600 19900 14800 18200 25727
Mw/Mt] 4.339 5.634 2.543 2.283 2.175 3.135 4.527 3.774 2.2
Extruder Back Pressure
(psi (MPa)) 1990
(13.7) 1654 (11.4) 1888
(13.0) 2050
(14.1) 2100 (14.5) 1781 (12.3) 2758
(19.0) 2125 (14.6) 2200
(15.2)
Motor Load (amps) 24 21 27 27 29 25 33 22 26
Haze (%) 8.8 7.8 19.1 37.5 25.2 10.7 11.9 10.8 12.8
Note: Density measured accordance with ASTM D-792 Ij measured accordance witti ASTM D-1238, Condilion igo^C/a.ie Kg 1,0 measured accordance with ASTM D-1238, Condition 190""C/10Kg Haze measured accordance with ASTM D-1003

Evaluation of Films Fabricated from the Polymer of Comparative Example C and Example 1
Films were produced on an Egan blown film line {2 inch (5 cm) extruder, 3 inch die (7.5 cm), 40 mil (1 mm) die gap. Table Two shows the fabrication conditions used for producing the blown fi"-Tr.s. Blown films were fabricated at 340°F (171^0) melt temperature. The back pressure and motor amps are similar for the polyrr.ers of Comparative Examples A and C and of Example 1. The polymer of Comparative Example B processed with a lower back pressure and motor amps.
Table Two

Description Comparative Example A Comparative Example B Comparative Example C Example 1
Melt Temp. rF(°C)) 339(171) 342 (172) 338(170) 341 (172)
Back Pressure (psi (MPa)) 1645±92 (11.3±0.6) 1484±73
(10.2±0.5) 1614±127
(11.1±0.9) 1531±112 (10.6±0.8)
Motor Load (amps) 21 19 24 24
Output Rate (lb/hr(kq/hrl) 31 (14) 31 (14) 31 (14) 31 (14)
Frost Line Height (in (cm)) 10-10.5
(25-27) 12 (30) 9-9.5 (23-24) 10
(25)
Layflat (in (cm)) 8 7/16 (21.4) 8 7/16 (21.4) 8 7/16 (21.4) 8 7/16
(21.4)
Gauge (mils (mm)) 1.4-1.6 (0.036-0.041) 1.4-1.6 (0.036-0.041) 1.4-1.6 (0.036-0.041) 1.4-1.6 (0.036-0.041)
Extruder Temperature Profiles: For samples Comparative Examples A, B and C: 300/300/325/325/325/325/325/325/325°F (149/149/163/163/163/163/163/163/163""C) For Example 1: 300/300/325/325/325/325/325/325/345°F {149/149/163/163/163/163/163/163/174^)

Table Three shows the mechanical and optical properties of the
resultant f il-.s.
Table Three

Description Comparative Example A Comparative Example B Comparative Example C Example 1
45 Dearee Gloss (%) 76.4±1.2 72.6±0.8 42.0±4.0 56.9±3.7
Haze (%) 7.9±0.1 6.3±0.2 17.3±0.4 9.2±1.4
Dart Impact Type A 90 82 115 74
CD Eimendorf Tear i 203±10 (q/mil (a/mm)) (8000±390) 99±14 (3900±551) 573±26 (23000±10001 223±13 (8800±512)
MD Eimendorf Tear j 396±35 (q/mil (a/mmi) ■ (15600±1400) 311±21 (12200±830) 196±67 (7720±2600) 56±9 (2200±350)
CD Etanqation (%) ! 591±16 503±46 706±3a 696±42
MD Eionqation (%) 370±15 198±14 649±16 566±13
CD Toughness , 723±33 fft-lMn^J/cmS)) " (1.605x10**±730) 534±74 (1.185x10"^iieOO) 1049±84 (2.329x104^1900) 873±74 (l.938xl0"*±1600>
MD Toughness 726±46 (ft-lb/in^ {J/cm3l) (reiaxlO-^ilOOOl 398±21 (8,836x103±470) 1305±68 (2.897x1 C^tl 500) 856±62 (1.900x10"*±1400)
CDTensiles 2179±87 (DsifMPal) n5.0±0.6t 1822±181 (12.6±1.21 3306±194 (■22.8±1.3) 2382±147 (16.4±1.0)
MDTensiles 3089±n4 (psi(MPa)) (21.3±0.791 3024±92
(20.8±0.63) 4541±176 (31.3±1.2) 3084±220
(21.3±1.5)
In order zo improve the haze of the blown films, blends with various polymers were investigated. Blends of the polymer of Comparative Example C and Example 1 were made with 10% LDPE 4012 [12 MI, ;.922 g/cm^). Table Four shows the fabrication conditions used for producing the blown films. These films were produced on the Egan blown film line (2 inch (5 cm) extruder, 3 inch (7.5 cm) die, 40 mil (1 mm) die gap). Blown films were fabricated ac 315°F dSV^C] melt temperature.

Table Four

Description Comparative Example A 90%
Comparative
Example C
and 10%
LDPE 4012 90%
Example 1
and 10%
LDPE 4012
Melt Temp. CF(°C)) 317(158) 312(156) 312(156)
Back Pressure (psi (MPa)) 1809±118 f12.5±0.8) 2169±177 (15.0±0.1) 2235±92 (15.4±0.6)
Motor Load (amps) 26 27 26
Output Rate (Ib/hr fkq/hr)) 32(14.5) 33(15) 33(15)
Frost Line Height (in (cm)) 8-8.5
(20-22) 7-9
(18-23) 7-8 (10-20)
Lavflat (in (cm)) 8 3/8(21) 8(20) 8(20)
Gauge (mils (mm)) 1.4-1.5
(0.036-0.038) 1.4-1.5 (0.036-0.038) 1.5-1.6 f 0.038-0.041)
45 Degree Gloss (%) 76.4±1.2 63.9±0.g 64.6±1.2
Haze (%) 7.9±0.1 9.U0.1 8.0±0.4
Extruder Temperature Profiles: 300/300/300/300/300/300/300/300/300°F
(149/149/149/149/149/149/149/149/149=0)
Table Fc-_r further shows Che optical properties of the resultant iilr.s . Films produced with the blends described above exhibited improved optical properties. In the case of the blend of 10 percent LDPE 4012 in the polymer of Example 1, this specific bler.d exhibited similar haze value as the Comparative Example A.
The pol\Tr.er of Example 1 was shown to not detrimentally affect the me::hanical properties of films prepared with heterogeneously branched linear low density polyethylene. Films were fabricated with blends of 12.5 weight percent of the polymers of Cr.mparative Examples A - C and Exan5>le 1, with 78.5 weight percer." DOWLEX 2045. Table Five shows fabrication conditions used for producing the blown films. These films were produced on the Gloucester blown film line (2.5 inch (6 cm) extruder, 6 inch (15 cm) die, 70 mil (1.8 mm) die gap). The processability of the blend of Example One with the LLDPE showed some irrLprovement in extruder back pressure over the blends of Comparative Examples A and B with the LLDPE.

Table Five

Description DOWLEX 2045+Comparative
Example A (7:1) DOWLEX
2045+
Comparative
Example B
(7:1) DOWLEX
2045+
Comparative
Example C
(7:1) DOWLEX
2045+
Example One
(7:1)
Melt Temp. {T(°C",1 400 (204) 397 (203) 398 (203) 398 (203)
Bacl Motor Load (amps) 84 85 86 87
Output Rate (!b/hr (kq/hrl) 110 (50) 110(50) 110(50) 110 (50)
Frost Line Height (in (cm)) 25 (64) 25 (64) 25 (64) 25 (64)
Gauge (mils (mm)> 1.5 fO.038) 1.5(0.038) 1.5(0.038) 1.5(0.038)
Extruder Temperature Profiles: 275/290/295/295/375/375/375/375 "F
(135/143/146/146/191/191/191/191 "C)

Table Si the resultant using the pol"_ of the blends B. The mecha following exc using the pol and higher ME blends using
: shows the mechanical and optical properties of
blown film. Optical properties of the blend .Tner of Example One was slightly inferior to that
using the polymer of Comparative Examples A and r.ical properties were comparable with the eptions noted: the films prepared from the blends -^•mer of Example One exhibited higher dart impact
Elmendorf tear that the films prepared from the -he polymers of Comparative Examples A and B.

Table Six

Description DOWLEX 2045+Comparativ e Example A ^7:1) DOWLEX 2045+
Comparative Exar7iDleBf7;1) DOWLEX 2045+
Comparative Example C (7:1) DOWLEX 2045+
Example One
(7:1)
45 Degree Gloss (%) 58.4±4.2 71.0±1,9 54.3±4.1 49.6±5.2
Haze (%) 11.5±0.5 7.9±0.4 13.8±0.2 14.5±0.6
Dart Impact Tvpe A 212 206 254 252
CD Elmendorf Tear (q) 736±47 742±16 685±20 648±41
MD Elmendorf Tear (a) 261±56 121±9 387±87 401±76
CD Elonqalion (%) 768±38 748±38 769±34 802±21
MD Elonqation (%) 585±17 602±18 620±16 605±17
CD Tensile Strength (Dsi (MPa)) 5795±514
(40.0±3.54) 5655±521 (39.0±3.59i 6050±509
(41.7±3.51) 6187±365
(42.7±2.52)
MD Tensile Strength (Dsi (MPa)) 6471*338 (44.6±2.331 6876±240 (47.4±1.65) 7310±318 (50.4±2.19) 6880±572
(47.4±3.94)
CD Toughness (ft-lb/in" (J/cm3)) 1584±161 (3.516x10"^±3570) 1530±146 (3.397x10"^±3240) 1618±171 (3.592x10"1±38001 1684±116 (3.738x10"*±2580)
MD Toughness 1426±91 (fi-lbfin^ / J/cm3)) ! (3.166x10^3=2020) 1575±60 (3.497x1 C^t 1330) 1542±94 (3.423x104±2090) 1400±135 (3.108x104±3000)
Films were prepared using the polymer of Example 2. The films were produced on an Egan blown film line (2 inch (5 cm) extruder, 3 inch (7.5 cm) die, 40 mil (1 mm) die gap). Blown films were fabricated at a SIS^F (157°C) melt temperature. Table Seven shows the fabrication conditions used for producing the blown fil-.s, as well as representative physical properties of the films.

Table Seven

DescriDtion Example 2 Comparative Example A
DieGaD (mils (mm)) 40(1) 40(1)
Blow Up Ratio 1.8 1.8
Uvflat (in (cm)) 8.5 (22) 8.5 (22)
Melt Temperature 312(156) 317(159)
Output Rate (Ib/hr (kq/hr)) 33(15) 33(15)
Bacl Motor Load (amp) 33 23
Frost Line Height (in (cm)) 7-8 (18-20) 7-8(18-20)
Gauge (mils (mm)) 1.5 (0.038) 1.5 (0.038)
45 Decree Gloss (%) 52.3±1.7 70.6±0.7
Clarity (%) 97.3±0.1 92.2±0.1
Haze (%) 11.9±0.4 9.0±0.2
Dart Impact Type A 54 66
Extruder Temperature Profiles: 300/300/300/300/300/300/300/300/300""F
(149/149/149/149/149/149/149/149/149°C)
The Polyir.ers of Comparative Examples D and E were fabricated inro blown films on an Egan blown film line (2 inch (5 cm) extruder, 3 inch (7.5 cm) die, 40 mil (1 mm) die gap). Blown films were fabricated at 315°P (157°C) melt temperature. Table Eigh" shows the fabrication conditions used for producing the blown fil-.s, and representative properties of the blown films.

Table Eight

Description Comparative
Example D Comparative Example E Comparative Example A
Die GaD{mils (mm)) 40(1) 40(1) 40(1)
Blow Up Ratio 1.8 1.8 1.8
Lavftat (in icm) 8.5 (22) 8.5 (22) 8.5 (22)
Melt Temperature
rFrcn 315 (157) 315(157) 311 (155)
Output Rate (Ib/hr (kQjhr)) 34(15) 34(15) 28(13)
Back Pressure
(psi (MPa)) 2000-2100
(13.8-14.5) 2000-2200 (13.8-15.2) 2000-2100 (13.8-14.5)
Motor Load (amp) 27 29 23
Frost Line Height (in (cmi) 6-6.5(15-16.5) 5.5-6(14-15) 4-5(10-13)
Gauqe{mils imm)) 1.5(0.038) 1.5 (0.038) 1.5 (0.038)
Haze(S) 37.5±2.6 25.2±1.7 9.2±0.1
Clarity (==) SS.9±1.2 90.4±Q.4 -
Extruder Temperature Profiles: 300/300/300/300/300/300/300/300/300""F
(149/149/149/149/149/149/149/149/149°C)
The back pressures for the polymers of Comparative Examples c and D are similar to that of the polymer of Comparative Example A. The motor loads for the polymers of Comparative Hj^ramples C and D are higher than that of Comparative Eicajnple A (although the output rate was lower for the polymer cf Comparative Example A, which will influence the motor load). Haze values for films prepared with the polymers of Comparative Examples C and D are significantly higher than that of a fil~. prepared with Comparative Example A
A concen-rate of Irgafos 168 and Irganox 1010 was dry blended with "he polymer of Example 3, such as to give 1200 ppm Irgafos 168 ar.d 300 ppm Irganox 1010 in the polymer. Blown films were also prepared with slip and antiblock concentrate, such as top cive 500 ppm erucamide slip agent and 2000 ppm White Mist an-iblock in the polymer. The films were produced on an Egan blown film line (2 inch (5 cm) extruder, 3 inch (7.5 cm) die, 40 mil (1.0 mm) die gap). Blown films were fabricated az 315°F (ISVC) melt temperature. Table Nine shows the fabrication conditions used for producing the blown films.

Table Nine

Description Example 3 + antioxidant Example 3 +antioxidant +10% LDPE 4012 Example 3 + antioxidant+10%
LDPE 4012 +Slip+Antiblock
Die Gap (mils (mm)) 40(1) 40(1) 40(1)
Blow Up Ratio 1.8 1.8 1.8
Lav(lat{in (cm)l 8.5 (22) 8.5 (22) 8.5 (22)
Melt Temperature 318(159) 310(154) 318(159)
Output Rate {Ib/hr fko/hr)) 30(14) 33(15) 30(14)
Back Pressure (psi (MPa)) 2000-2250 (13.8-15.5) 2000-2200
(13.8-15.2) 1900-2400 (13.1-16.5)
Motor Load (amo) 22 21 23
Frost Line Heignt (in (cm)) 5(13) 6(15) 6(15)
Gauge (mils (mm)) 1.5-1.6
( 1.5 1.5-1.6
Extruder Temperature Profiles: 300/300/300/300/300/300/300/300/300°F
(149/149/149/149/149/149/149/149/149°C)
Table Ten shows the optical and mechanical properties of films prepared with the polymer of Example 3, with various combinations ~t additives as described above. Table Ten illustrates cr.e improvement on opticals which results from the incorporation of LDPE into the polymer, and the negative affect on opticals wnich results from the addition of slip and antiblock adcjirives.

Table Ten

Description Example 3 -t-antioxidant Example 3
+antioxidant
+10%LDPE4012 Example 3 + antioxidant+10%
LOPE 4012 +Slip+Antlblocl Haze (%) 10.8±0.7 9.3±1.0 10.9±O.6
CD Elmendorf Tear (q) NA 225±16 264±44
MD Elmendorf Tear (q) NA 91 ±27 92±37
CD Elonqation(%) NA 740±43 690±28
MD Elonqation(%) NA 520±3a 539±36
CD Tensile Strength (psi (MPa)) NA 2893±335 (19.94±2.31) 2559±207 (17.64±1.43)
MD Tensile Strength (psi (MPat) NA 3551±300 (24.48±2.07) 3887±352 (26.80±2.42)
CD Toughness (H-)b/in^ (J/cm3)) NA 680±104 n.51x104±2300) 576±50 (1.28x10"*±1100)
MD Toughness (ft-lb/in" (J/cm3)) NA 627±67 f1.39x104±1500) 690±76 (1.53x104±1700)
- AO package contains 1200 ppm Irgafos 168 and 300 ppm Irganox 1010 ^ - Slip pacl^age contains 500 ppm Erucamide ^ - Antiblock package contains 2000 ppm White Mist
As illusirated above, the polymers of Examples 1-3 exhibit mechanical properties which are improved over those of the Comparative Examples A and B, while not degrading optical performance ro an unacceptable level. Figures 1 and ^ provide plots of I; versus M^ and of I1.0/I2 versus Mw/Mn for the polymers of Examples 1 - 3, as well as of polymers of the other examples and comparative examples. As set forth in Figure 1, the polymers of Examples 1-3 will be characterized as satisfying the following inequality:
I5 Further, as set forth in Figure 2, the polymers of Examples 1-3 will be characterized as satisfying the following inequality:
I10/I2 > [1-5 * Mw/Mn] + 2.59

High Processir-g Polymers having a Fractional Melt Index
The polyners of Examples 5-8 were prepared with a constrained geometry catalyst in accordance with the procedures of U.S. Paten- No. 5,272,236 and U.S. Patent No. 5,278,272. In each case, the catalyst employed t-butylamido) dimethyl) T| ^-tetramethylcyclopentadienyl) silanetitanium (II) 1,3-pentadiene catalyst, activated with trispentafluorophenylborane and triisopropylaluminum modified methylalumoxane (MKAO, available from Akzo Chemical) . For instance, the polymer of Example 8 may be prepared utilizing the following process conditions:

Solvent Feed (Kg/h) 16.36
Ethylene Feed (Kg/h) 1.82
Hydrogen Feed (SCCM) 0
Butene Feed (kg/h) 0.155
Ethylene Conv. % 95.5
Feed Temp (C) 15
Reactor Temp [C) 132
Catalyst Flow { kg/h) 2.39 X 10"°
Primary
Co-catalyst Flow (kg/h) 6.86 X lO"""
Secondare" Co-catalyst Flow (kg/h) 1.14 X 10"^
The pol\-:r,ers of Comparative Examples A and B were commercially available low density polyethylene.
A description of the properties of the polymers of Examples 1 - 5, as well as the polymers of Comparative Examples A and B, as described a.hove. are set forth in the following Table Eleven.

Table Eleven

Comparative Example A Comparative Example B Example 5 Example 6 Example 7 Example 8
Comonomer Type - - Hexene Hexene Butene Butene
l?{q/10min) 0.32 1:1-1 0.19 0.68 0.30 0.63 0.50
lu/l.
^0.7 13.3 16.1 14.4 13.7
Density (q/cc) 0.9217 0.919 0.9227 0.9205 0.9159 0.918
Melting Temperature ("0) 111.98 108.55 114.06 113.57 107.89 110.5
Crystallization Temperature ("C) 97.9 95.2 100.35 100.76 92.93 95.96
Crvstallinily {%) 49.5 48.2 50.10 49.5 45.8 47.0
Weight Averaqe Molecular Weight (Mw) 137900 166200 80700 89700 80200 82800
Number Averaqe Molecular Weight (Mn) 22200 22100 32400 35800 33500 32500
Mw/Mn 6.211 7.520 2.490 2.505 2.394 2.547
Haze 13.5 19.7 9.9 7.3 - -
Note: Density measured accordance with ASTM D-792 U measured accordance with ASTM D-1238, Condition 190""C/2,16 Kg I10 measured accordance with ASTM D-1238, Condition 190°G/10Kg Haze measured accordance with ASTM D-1003

The pol\—.ers of Example 5 and of Comparative Examples A and B were fai;ricated into blown films. Blown films were fabricated at 320°F (I6OOC) melt temperature. Table Twelve shows the fabrication conditions used for producing the blown films, as well as the mechanical and optical properties of the resultant fil—s.
Table Twelve

Description
Melt Temp. TF t --C))
Back Pressure (psi (MPa))
Motor Load (amps)
Output Rate (lb/hr(kg/hrj^
Frost Line Height (in (cm))
Layflat (in (cm))
Gauge (mils (mm))
45 Degree Gloss (%)
Haze(%)
Dart Impact Tyce A
CD Elmendorf Tear
(g^"^ii)
ear
MD Elmendorf (g/mil)
.!^
CD Elongation
MD Elongation "="0)
CD Toughness (ft-lb/in3 (J/cm^))
MD Toughness (ft-lb/in3 (J/cm3))
CD Tensiles
(psi (MPa))
MD Tensiles
(psi (MPa)l
CD Shrinkage I"-o)"
MD Shrinkage! ="=.)"

Comparative Example A
323(162)
3727±130 (25.69±0.90)
40
37(17)
10.5(26.7)
14 (36)
2.8-3.2
(0.07-0.08)
46.1±1.1
16.1 ±0.2
470
70±14
39±24
502±12
340±30
918±30 (2.038x104±670)
745±88 (1.654xlO^±19QO)
3773±78 (26.01 ±0.53)
3355±213 (23.13±1.47)
36.5
71.5

Comparative Example B
319(159)
3747±150
(25.B±1.0)
38
37(17)
10-10.5 (25-26.7)
14(36)
2.8-3.2 (0.07-0.08)
18.5±0.6
32.8±0.3
444
42±12
33±21
443±21
327±42
732±50 (1.625x10"*±1100)
725±120 (1.610x104±2700)
3196±137 (22.03±0.94)
3263±236 (22.50±1.63)
42.4
73.4

Example 5
322(161)
3811±174 (26.3±1.2)
45
38(17)
8(20)
14(36)
2.8-3.2 (0.07-0.08)
62.5±0.9
10.1 ±0.6
372
363±24
157±31
740±12
690±28
1499±72 (3.328x1Q"*±1600)
1531±110 (3.399x10^±2400)
4833±235 (33.3±1.62)
5067±278 (34.86±1.92)
31.1
53.2

Extruder Temperature Profile: 300/300/300/300/300/300/300/300/300°F
(149/149/149/149/149/149/149/149/149°C " CD and MD shrinkages were measured at 125°C, 20 seconds, 4 inchx4 inch (10 cm X 10 cm) film sample

Optical properties of the films prepared with the polymers of Comparative Examples A and B differ. The film prepared with the polymer of Comparative Example A exhibits much better optical properties than that of the film prepared with the polymer of Comparative Example B. The film prepared with the polymer of Example 5 exhibited better optical properties, tensile (ultirr.ate tensile strength and toughness) , and Elmendorf tear values than the films of either of the polymers of Comparative Examples A or B. Bubble stability during processing was similar for each of the films prepared.
Optical properties are further improved by fabricating the films at a higher temperature. Blown films were fabricated at a melt temperauure of 375°F from the polymers of Comparative Examples A and B, and from the polymer of Examples 5 and 6. Table Thirteen sets forth the fabrication conditions used for producing the blown films, as well as the mechanical and optical properties of the resultant films.

Table Thirteen

Description Comparative Example A Comparative Example B Example 5 Example 6
Melt Temp. (°F CO) 376(191) 379(193) 377 (192) 400 (204)
Back Pressure (psi (MPai) 3233±139
(22.28±0.961 3296±129
(22.72±0.89) 3143±150 (21.67±1.03) 3549±167
(24.47±1.15)
Motor Load (amps) 34 33 39 44
Output Rate (Ib/hr (kq/hr)) 37(17) 37 (17) 39(18) 38(17)
Frost Line Height (in (cml) 10.5(26.7) 10 (25) 7(18) 7(18)
Lavflat((n(cmii 14 (36) 14(36) 14 Gauge (mils (mm|) 2.8-3.2 {0.07-0.081 2.8-3.2 (0.07-0.08)_ 2.8-3.2
(0.07-0.08) 2.8-3.2 (0.07-0.08)
45 Degree Gloss (%) 55.4±1.7 33.2±0.8 66.4±2.4 72.1 ±0.6
Haze(%) 13.5±0.1 19.7±0.2 9.9±0.2 7.3±0.5
Dart Impact Tvoe A 428 366 346 374
CD Elmendorf Tear (q/mil) 10U15 102±72 254±44 357±29
MD EJmendorf Tear (a/mil) 44±22 44±14 181±44 177±51
CD Elongation (%1 538±6 458±45 666±29 747±23
MD Elonqation (%) 423±20 500±31 651±34 703±30
CD Toughness (ft-lb/in^ (J/cm3)) 927±22 {2.058x104±4.90^ ■ 877±126 (1.947x10"f±2800) 1267±104 (1.001x10"*±2300) 1712±109 (3.801 x10**±24000)
MD Toughness (ft-lb/in^ (J/cm3)) 943±63 (2.039x10^*114001 1000±95 (2.093x10*** 14001 1345±143 (2.986x10^^13200) 1662±159 (3.690x10"*±3500)
CD Tensiles (psi (MPa)) 3613±110 (24.91*0.76) 3921±360 (27.04±2.48) 4552±325
(31.38±2.24) 5958±212
(41.07±1.46)
MD Tensiles (psi (MPa)) 3715±145 (25.61*1.0) 3478±230 (23.98±1.59) 4725±421 (32.57±2.90) 5839i401 (40.25±2.76)
CD Shrinkage (%r* 35.0 39.0 28.1 32.1
MD Shrinkaqe (%)" 69.5 66.5 50.8 56.7
Extruder Temperature Profiles: 300/325/350/360/360/360/360/360/370/370 °F
(149/163/177/182/182/182/182/182/188/188""C) "• CD and MD Shnnkage were measured at 125°C, 20 seconds, 4 inch x4 inch film sample
A comparison of Tables Twelve and Thirteen illustrates that, in the case of the films prepared with the polymers of Comparative Examples A and B and with the polymer of Example 5, the films fabricated at higher melt temperature exhibited better optical properties (haze and gloss) than the films fabricated at lower melt temperature. Further, the films prepared v."ith the polymers of Examples 5 and 6 exhibited better optical, tensile, and Elraendorf tear properties than the films fabricated with the polymers of Comparative Examples A and B.

Bubble stability during processing was similar for the fabrication cf each of the films.
High Processing Polymers having a Melt Index of from 1 to 2 g/lQ minutes
The pol\-:r.er of Example 9 is a substantially linear ethylene/l-octene interpolymer prepared in a single solution polymerization reactor, in accordance with the procedures of U.S. Patent Xos. 5,272,236 and 5,278,272.
The polvTTier product of Polymer 9 may be produced in a solution polymerization process using a well-mixed recirculating loop reactor.
The ethylene and the hydrogen (as well as any ethylene and hydrogen which are recycled from the separator, are combined into one stream before being introduced into the diluent mixture, a mixture of Cg-Cio saturated hydrocarbons, such as ISOPAR™-E (available from Exxon Chemical Company) and the comonomer, l-zct&ne.
The metal complex and cocatalysts are combined into a single stream and are also continuously injected into the reactor- The catalyst employed is (t-butylamido) dimethyl (r|^-tetramethylcyclopentadienyl) silanetItanium (IV) dimethyl, activated with trispentafluorophenylborane (available from Boulder Scier.-ific as a 3 wt% solution in ISOPAR-E mixed hydrocarbon) and triisopropylaluminum modified methylalumoxane (MMAO Type 3A, available from Akzo Nobel Chemical Inc. as a solution in heptane having 2 wt% aluminum).
Sufficient residence time is allowed for the metal complex and cocatalys- to react prior to introduction into the polymerizaticr. reactor. The reactor pressure is held constant at about 475 psig.
After pclymerization, the reactor exit stream is introduced ir.-o a separator where the molten polymer is separated frcr-. the unreacted comonomer {s) , unreacted ethylene, unreacted hydrogen, and diluent mixture stream, which is in turn recycled for combination with fresh comonomer, ethylene.

hydrogen, and diluent, for introduction into the reactor. The molten polymer is subsequently strand chopped or pelletized, and, after being cooled in a water bath or pelletizer, the solid pellets are collected. Table Fourteen describes the polymerization conditions and the resultant polymer properties
Table foorbecn

Ethylene fresh feed rate (kg/hr) 68
Fresh octene feed rate (kg/hr) 8.6
T::t:al octene concentration in recycle {weight %) [Estimated) 5.3
Fresh hydrogen feed rate (standard c—-/min) about 400
Sclvent and octene feed rate (kg/hr) 227
Ethylene conversion rate (wt %) 96
Feactor temperature (°C) 146
Feed temperature (°C) 10
C = T:alyst flow rate (kg/hr) 0.91
Primary cocatalyst to catalyst molar ra-io (B:Ti) 3.5
Secondary cocatalyst to catalyst rr-zlar ratio (Al:Ti) 5

Polymers replace HP-LE: liner and bak-the extruder : hightly brand to clarity gr"
(3) mechanica. density polye Table Fi Example 9, as
(LDPE 503, a :

such as those of Example 9 are targeted to -S in optical grade film markets, such as clarity =ry film. Performance requirements include: (1) :rocessability and bubble stability similar to :ed low density polyethylene; (2) optics similar ide highly branched low density polyethylene; and - properties better than highly branched low ihylene. :teen sets forth the properties of the Polymer of
well as of the polymers of Comparative Examples F iighly branched low density polyethylene.

available trcrr. The Dow Chemical Company) ) and G (DOWLEX™ linear low density polyethylene (available from The Dow Chemical Company). Table Fifteen further reports performance attributes of these polymers and of blown films prepared from these polymer-.
Table Fifteen

Comparative Example F Example 9 Comparative Example G
Melt Index, g/10 min. 1.9 1.6 1.00
I10/I2 ~ 13 8.0
Melt Tension, g 3.6 2.5 1.4
Density, g/cc 0.922 0.923 0.920
Mechanical Properties:
MD Elmendorf Tear, g 414 287 691
CD Elmendorf Tear, s 310 729 819
Dart Impact, g 103 172 236
Extrudabilitv:
Melt Temp.. C 379 390 462
Extruder Pressure, DSI (MPa) 3390 (23.4) 3950 (27.2) 5040 (34.7)
Motor Amp. 47 59 69
Optics:
Haze, % 5.6 4.6 12
As set forth in Table Fifteen, the polymer of Example 9 exhibits optical properties which exceed those of Comparative Example F, e.-"i::ibit a processability and mechanical properties which are generally intermediate that of Comparative Examples F and G.


WE CLAIM:
1. A film having at least one layer comprising a homogeneous interpolymer of
ethylene and at least one comonomer selected from the group consisting of C3-
C20 a-olefins, dynes, and cycloalkenes, wherein the interpolymer is
characterized as having:
a) a density of from 0.910 to 0.930 g/cm’, as measured according to the procedures of ASTM D792;
b) a melt index (I2) of from 0.05 to 10 g/10 minutes, as measured according to procedures of ASTM D-I238, Condition I90""C/2.I6 Kg formerly known as Condition E;
c) an I10/I2 of from 9 to 20, with IO measured according to the procedures of ASTM D-1238, Condition 190’/10 Kg formerly known as Condition N;
d) a molecular weight distribution, M’/Mn, of from 2.1 to 5 as measured using narrow molecular weight distribution polystyrene standards in conjunction with their elution volumes; and
e) wherein the interpolymer is further characterized as having a single crystallization peak between 45"C and 98""C and having a Crystallization Temperature Breadth Index (CTBI) of less than 18°C, as determined by temperature rising elution fractionation (TREF).
2. The film as claimed in claim 1, wherein the interpolymer is a substantially
linear polymer having:
a) a molecular weight distribution, Mw/Mn, as determined by gel permeation chromatography and defined by the equation:
(M,/M,)
b) a gas extrusion rheology such that the critical shear rate at onset of surface melt fracture for the interpolymer is at least 50 percent greater than the critical shear rate at the onset of surface melt fracture for a linear ethylene polymer, wherein the interpolymer and the linear ethylene polymer comprise the same comonomer or comonomers, wherein the linear ethylene polymer has an I2, Me/Mn and density within ten percent of the interpolymer, and wherein the respective critical shear rates of the interpolymer and the linear ethylene polymer are measured at the same melt temperature using a gas extrusion rheumatic.
3. The film as claimed in claim 1, wherein the interpolymer has 0.01 to 3 long chain branches/1000 carbons.
4. The film as claimed in claim 1, wherein the interpolymer yields a gel permeation chromatogram which exhibits two peaks.
5. The film as claimed in claim 4, wherein the interpolymer is prepared in two polymerization reactors, each of which contains a single site constrained geometry or metallocene catalyst.
6. The film as claimed in claim 5, wherein the interpolymer, upon fractionation by gel permeation chromatography, is characterized as comprising:

a) from 25 to 90 percent of a first polymer fraction having a melt index {I2) of from 0.05 to 1.0 g/10 minutes; and
b) from 10 to 75 percent of a second polymer fraction having a melt index {I2) of at least 30 g/10 minutes.

7. The film as claimed in claim 1, wherein the interpolymer has an overall melt index (I2) of from 1.0 to 7.0 g/10 minutes.
8. The film as claimed in claim 5, wherein the interpolymer satisfies the following
inequalities:
a) l3 b) ho/l2>U-5 * M.JM„]+2.59.
9. The film as claimed in claim 5, wherein the interpolymer, upon fractionation by
gel permeation chromatography, comprises:
a. from 30 to 85 percent of a first polymer fraction having a melt index (I3)
of from 0.05 to 1.0 g/10 minutes; and
b. from 15 to 70 percent of a second polymer fraction having a melt index
(I2) of at least 30 g/10 minutes.
10. The film as claimed in claim 2, wherein the interpolymer has:
a. an I2 of from 0.05 to less than 2.5 g/10 minutes,
b. an I10/I2 of at least 12.5, and
c. an Mi’Mn of from 2.1 to 3.0.
11. A process for preparing a blown fihn comprising:
a. melting an interpolymer to a temperature of 300 to 350°F (149 to
b. extruding the polymer at the rate of 15 to 100 Ib/hr (6.8 to 45 kg/hr)
through a die having a 30 to 100 mil (0.76 to 2.5 mm) die gap.

c. blowing the film to into a bubble, at a blow-up-ratio of 1.3:1 to 2.5:1, to
form a 0.5 to 4 mil (0.01 to 0,1 mm) gauge film, and
d. cooling the film by means external to the bubble, wherein the
interpolymer is an interpolymer of ethylene and at least one comonomer
selected from the group consisting of C3-C20 a-olefins, dienes, and
cycloalkenes has:
i. a density of from 0.910 to 0.930 g/cmii. a melt index (I2) of from 0.2 to 10 g/10 minutes, iii. an IK/IJ of from 9 to 20,
iv. a molecular weight distribution, M’/M’ of from 2.1 to 5; and V. a single crystallization peak between 45°C and 98""C and having a CTBI of less than 18°C, as determined by TEIEF.
12. A process for preparing a blown fen comprising:
a. melting an interpolymer to a temperature of 300 to 400°F (149 to
204°C),
b. extruding the polymer at the rate of 15 to 100 Ib/hr (6.8 to 45 kg/hr)
through a die having a 30 to 100 mil (0.76 to 2.5 mm) die gap,
c. blowing the film into a bubble, at a blow-up-ratio of 2:1 to 4:1, to form a
2 to 5 miJ {0.05 to 0.1 mm) gauge film, and
d. cooling the film by means external to the bubble, wherein the
interpolymer is an interpolymer of ethylene and at least one comonomer
selected from the group consisting of C3-C20 a-olefins, dienes, and
cycloalkenes has:
i. a density of from 0,910 to 0.930 g/cm’
ii. a melt index (I2) of from 0.05 to 2.5 g/10 minutes,
iii an I10/I2 of from 12.5 to 20,

iv. a molecular weight distribution, M’/Mn of from 2.1 to 3; and V. a single crystallization peak between 45°C and 98°C and having a CTBI of less than 18°C, as determined by TREF.
13. A film having at least one layer substantially as herein described with reference
to the accompanying drawings.
14. A process for preparing a blown film substantially as herein described with
reference to the accompanying drawings.

Documents:

1570-mas-1998 abstract.pdf

1570-mas-1998 assignment.pdf

1570-mas-1998 claims-duplicate.pdf

1570-mas-1998 claims.pdf

1570-mas-1998 correspondences-others.pdf

1570-mas-1998 correspondences-po.pdf

1570-mas-1998 drawings-duplicate.pdf

1570-mas-1998 drawings.pdf

1570-mas-1998 form-19.pdf

1570-mas-1998 form-2.pdf

1570-mas-1998 form-26.pdf

1570-mas-1998 form-4.pdf

1570-mas-1998 form-6.pdf

1570-mas-1998 pct search report.pdf

1570-mas-1998 petition.pdf

1570-mas-1998 description (complete)-duplicate.pdf

1570-mas-1998 description (complete).pdf


Patent Number 217249
Indian Patent Application Number 1570/MAS/1998
PG Journal Number 21/2008
Publication Date 23-May-2008
Grant Date 26-Mar-2008
Date of Filing 14-Jul-1998
Name of Patentee DOW GLOBAL TECHNOLOGIES INC.
Applicant Address WASHINGTON STREET, 1790 BUILDING, MIDLAND, MICHIGAN 48674,
Inventors:
# Inventor's Name Inventor's Address
1 SHIH-YAW LAI 36 GENTLE DRIVE, SINGAPORE 309239,
2 LI-MIN TAU 113 POINCIANA STREET, LAKE JACKSON, TEXAS 77566,
3 SEEMA V KARANDE 215 TEAROSE LANE LAKE JACKSON, TEXAS 77566,
4 LONNIE G HAZLITT 110 WEDGEWOOD LAKE JACKSON, TEXAS 77566,
5 PRADEEP JAIN 308 BANYAN DRIVE LAKE JACKSON, TEXAS 77566,
6 KAELYN D KOCH 113 WATERLILLY STREET LAKE JACKSON, TEXAS 77566,
PCT International Classification Number C08J 05/18
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 60/055,902 1997-08-15 U.S.A.