(19)
(11)EP 3 377 421 B1

(12)EUROPEAN PATENT SPECIFICATION

(45)Mention of the grant of the patent:
23.12.2020 Bulletin 2020/52

(21)Application number: 16794139.2

(22)Date of filing:  27.10.2016
(51)International Patent Classification (IPC): 
B65D 47/08(2006.01)
C08L 23/04(2006.01)
(86)International application number:
PCT/US2016/058971
(87)International publication number:
WO 2017/087131 (26.05.2017 Gazette  2017/21)

(54)

POLYETHYLENE COMPOSITIONS HAVING LIVING HINGE PROPERTIES

POLYETHYLENZUSAMMENSETZUNG MIT AKTIVEN GELENKEIGENSCHAFTEN

COMPOSITIONS DE POLYÉTHYLÈNE PRÉSENTANT DES PROPRIÉTÉS DE CHARNIÈRE VIVANTE


(84)Designated Contracting States:
AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

(30)Priority: 19.11.2015 US 201562257283 P

(43)Date of publication of application:
26.09.2018 Bulletin 2018/39

(73)Proprietor: Dow Global Technologies LLC
Midland, MI 48674 (US)

(72)Inventors:
  • LIN, Yijian
    Lake Jackson, TX 77566 (US)
  • HOGAN, Todd A.
    Midland, MI 48674 (US)
  • MARKOVICH, Ronald P.
    Freeport, TX 77062 (US)

(74)Representative: Boult Wade Tennant LLP 
Salisbury Square House 8 Salisbury Square
London EC4Y 8AP
London EC4Y 8AP (GB)


(56)References cited: : 
WO-A1-2009/097222
CA-A1- 2 798 854
US-A1- 2013 331 496
WO-A1-2015/132680
US-A1- 2005 256 271
US-A1- 2015 259 519
  
      
    Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention).


    Description

    TECHNICAL FIELD



    [0001] Embodiments of the present disclosure generally relate to polyethylene compositions, and more particularly to high density polyethylene compositions suitable for use in living hinge applications.

    BACKGROUND



    [0002] A living hinge is a thin, flexible hinge connecting two relatively rigid parts. It is usually made from the same material as the rigid parts. It may be used to join rigid parts of a container, allowing them to bend along the line of the hinge. Polypropylene (PP) has traditionally dominated the living-hinge dispensing closure market as it is easily processed and has good hinge durability characteristics. Additionally, it is widely available and historically had favorable economics relative to polyethylene when utilized to these ends. These attributes coupled with PP's overall balance of properties make it a frequent choice for living-hinge closure applications, as well as many molding applications.

    [0003] In addition, it has become more desirable to have a closure that is made from the same type of polymer as the bottle to enable recycling of the entire container. Further, polyethylene has not always been a suitable replacement of PP due to poor living hinge durability, especially when a high melt index is needed for polyethylene to have good processability. That is, polyethylene has not necessarily proven to be mechanically strong enough to last a large number of flexing cycles.

    [0004] Accordingly, it may be desirable to produce polyethylene compositions having improved processability and/or longer living hinge durability.

    SUMMARY



    [0005] Disclosed in embodiments herein are polyethylene compositions suitable for use in living hinge components. The compositions comprise a first ethylene-based polymer component, wherein the first ethylene-based polymer component has a density of from 0.940 g/cc to less than 0.960 g/cc, a melt index, I2.16, of less than 0.5 g/10 min, and a weight average molecular weight, Mw,cc, as measured by gel permeation chromatography using conventional calibration of greater than or equal to 200,000 g/mol, and a second ethylene-based polymer component, wherein the second ethylene-based polymer component has a density from 0.940 g/cc to less than 0.970 g/cc and a melt index, 12.16 of 20 - 150 g/10 min wherein the composition has an overall density of from 0.945 g/cc to 0.960 g/cc and an overall melt index, I2.16, of from 10 g/10 min to 70 g/10 min.

    [0006] Also disclosed in embodiments herein are living hinge components. The living hinge components comprise a polyethylene composition, the composition comprising a first ethylene-based polymer component, the first ethylene-based polymer component has a density of from 0.940 g/cc to less than 0.960 g/cc, a melt index, I2.16, of less than 0.5 g/10 min, and a weight average molecular weight, Mw,cc, as measured by gel permeation chromatography using conventional calibration of greater than or equal to 200,000 g/mol, and a second ethylene-based polymer component, wherein the second ethylene-based polymer component has a density from 0.940 g/cc to less than 0.970 g/cc and a melt index, 12.16 of 20 - 150 g/10 min wherein the composition has an overall density of from 0.945 g/cc to 0.960 g/cc and an overall melt index, I2.16, of from 10 g/10 min to 70 g/10 min.

    [0007] Additional features and advantages of the embodiments will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments described herein, including the detailed description which follows, the claims, as well as the appended drawings.

    [0008] It is to be understood that both the foregoing and the following description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein, and together with the description serve to explain the principles and operations of the claimed subject matter.

    BRIEF DESCRIPTION OF THE DRAWINGS



    [0009] 

    FIG. 1 pictorially depicts the geometry of a living hinge made according to one or more embodiments shown or described herein.

    FIG. 2 pictorially depicts the rotation of the hinge durability test on a living hinge made according to one or more embodiments shown or described herein.


    DETAILED DESCRIPTION



    [0010] Reference will now be made in detail to embodiments of polyethylene compositions and living hinge components. The polyethylene compositions may be used to form living hinge components. It is noted, however, that this is merely an illustrative implementation of the embodiments described herein. The embodiments are applicable to other technologies that are susceptible to similar problems as those discussed above. For example, the polyethylene compositions described herein may be used in other closure applications, such as, hot-fill and/or aseptic closure applications.

    [0011] Disclosed is a composition suitable for use in a molded component, particularly, a living hinge component. The composition includes a first ethylene-based polymer component and a second ethylene-based polymer component. The term "ethylene-based" as used herein means that the polymer component contains more than 50 weight percent of ethylene monomer in polymerized form (based on the total amount of polymerizable monomers) and, optionally, may contain at least one comonomer.

    First Ethylene-Based Polymer Component



    [0012] In embodiments herein, the first ethylene-based polymer component of the composition may be an ethylene-based interpolymer, ethylene homopolymer, ethylene/α-olefin interpolymer, homogeneously branched ethylene-based interpolymer or copolymer, or a heterogeneously branched ethylene-based interpolymer or copolymer. The first ethylene-based polymer component may be unimodal or may be bimodal, where it has a molecular weight distribution in a gel permeation chromatography curve that exhibits two peaks. Descriptions of exemplary bimodal resins, including how to manufacture, are described in U.S. 8,344,068 and WO/2014/126839. Homogeneously branched interpolymers may be produced, for example, by single-site catalyst systems, and contain a substantially homogeneous distribution of comonomer among the molecules of the interpolymer. Heterogeneously branched interpolymers may be produced by Ziegler-Natta type catalysts or chromium-based catalysts, and contain a non-homogeneous distribution of comonomer among the molecules of the interpolymer. The comonomer may be an α-olefin. In some embodiments, the first ethylene-based polymer component may be polymerized using Ziegler-Natta catalysts to form a bimodal polymer. In other embodiments, the first ethylene-based polymer component may be polymerized using chromium-based catalysts. Suitable methods to polymerize ethylene monomers using chromium-based catalysts are generally known in the art, and may include gas-phase, solution phase and slurry-phase polymerization processes. In some embodiments, the first ethylene-based polymer component may be polymerized in a gas-phase process, using a chromium catalyst, and in particular, a titanated chromium catalyst. Chromium catalysts and polymerization methods are further described in EP2218751, WO2004/094489, US 4,100,105, and US 6,022,933, which are incorporated herein in its entirety by reference. In some embodiments, the first ethylene-based polymer component is an ethylene/a-olefin interpolymer, and further an ethylene/a-olefin copolymer. Trace amounts of impurities, for example, catalyst residues, may be incorporated into and/or within a polymer.

    [0013] As used herein, "interpolymer" refers to polymers prepared by the polymerization of at least two different types of monomers. The term "interpolymer" can include copolymers, which is used to refer to polymers prepared from two different types of monomers, and polymers prepared from more than two different types of monomers. The term "ethylene/α-olefin interpolymer" refers to an ethylene-based polymer that comprises, in polymerized form, a majority weight percent ethylene (based on the weight of interpolymer), an α-olefin comonomer, and optionally, one or more additional comonomers. "Ethylene/alpha-olefin copolymer" refers to a polymer comprising repeating units derived from ethylene and one alpha-olefin comonomer. "Ethylene homopolymer" refers to a polymer that consists essentially of repeating units derived from ethylene. In some examples, an ethylene homopolymer contains at least 99 percent by weight of ethylene units, at least 99.5% by weight of ethylene units, at least 99.8% by weight of ethylene units, or at least 99.9% by weight of ethylene units.

    [0014] Suitable α-olefins may include those containing 3 to 20 carbon atoms (C3-C20). In some embodiments, the α-olefin may be a C4-C20 α-olefin, a C4-C12 α-olefin, a C3-C10 α-olefin, a C3-C8 α-olefin, a C4-C8 α-olefin, or a C6-C8 α-olefin. In some embodiments, α-olefins are selected from the group consisting of propylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene and 1-decene. In other embodiments, α-olefins are selected from the group consisting of propylene, 1-butene, 1-hexene, 4-methyl-1-pentene, and 1-octene. In further embodiments, α-olefins are selected from the group consisting of 4-methyl-1-pentene, 1-butene and 1-hexene.

    [0015] Exemplary ethylene/a-olefin interpolymers may include, but are not limited to, ethylene/butene-1 (EB) copolymers, ethylene/hexene-1 (EH) copolymers, ethylene/octene-1 (EO) copolymers, ethylene/alpha-olefin/diene modified (EAODM) interpolymers such as ethylene/propylene/diene modified (EPDM) interpolymers and ethylene/propylene/octene terpolymers. In some embodiments, the ethylene/a-olefin interpolymers are selected from the group consisting of EB, EH and EO copolymers. In other embodiments, the ethylene/α-olefin interpolymers are selected from the group consisting of EB and EH copolymers.

    [0016] In embodiments herein, the density of the first ethylene-based polymer component is from 0.940 g/cc to less than 0.960 g/cc. All individual values and subranges of 0.940 to less than 0.960 g/cc are included and disclosed herein. For example, in some embodiments, the density of the first ethylene-based polymer component is from 0.942 to less than 0.960 g/cc. In other embodiments, the density of the first ethylene-based polymer component is from 0.945 to less than 0.960 g/cc. In further embodiments, the density of the first ethylene-based polymer component is from 0.947 to less than 0.960 g/cc. Densities disclosed herein for ethylene-based polymers are determined according to ASTM D-792.

    [0017] In embodiments herein, the melt index, or I2.16, of the first ethylene-based polymer component is less than 0.5 g/10 min. All individual values and subranges of less than 0.5 g/10 min are included and disclosed herein. For example, in some embodiments, the melt index of the first ethylene-based polymer component is less than 0.4 g/10 min. In other embodiments, the melt index of the first ethylene-based polymer component is less than 0.3 g/10 min. In further embodiments, the melt index of the first ethylene-based polymer component is less than 0.2 g/10 min. Melt index, or I2.16, for ethylene-based polymer components is determined according to ASTM D1238 at 190°C, 2.16 kg.

    [0018] In embodiments herein, the first ethylene-based polymer component may have a melt index, I21.6, of from 1 to 20 g/10 min. All individual values and subranges of 1 to 20 g/10 min are included and disclosed herein. For example, in some embodiments, the first ethylene-based polymer component may have a melt index, I21.6, of from 2 to 18 g/10 min. In other embodiments, the first ethylene-based polymer component may have a melt index, I21.6, of from 3 to 16 g/10 min. Melt index, or I21.6, for ethylene-based polymer components is determined according to ASTM D1238 at 190°C, 21.6 kg.

    [0019] In embodiments herein, the first ethylene-based polymer component may have a weight average molecular weight (Mw,cc, where the subscript "cc" means conventional calibration) of greater than or equal to 200,000 g/mol. All individual values and subranges of greater than or equal to 200,000 g/mol are included and disclosed herein. For example, in some embodiments, the first ethylene-based polymer component may have a weight average molecular weight (Mw,cc) of greater than or equal to 205,000 g/mol. In other embodiments, the first ethylene-based polymer component may have a weight average molecular weight (Mw,cc) of greater than or equal to 210,000 g/mol. In further embodiments, the first ethylene-based polymer component may have a weight average molecular weight (Mw,cc) of greater than or equal to 215,000 g/mol, greater than or equal to 220,000 g/mol, or greater than or equal to 225,000 g/mol. The weight average molecular weight (Mw,cc) may be determined by Gel Permeation Chromatography (GPC).

    [0020] In embodiments herein, the first ethylene-based polymer component may have a molecular weight distribution (Mw,cc/Mn,cc where Mn,cc is number average molecular weight as measured by gel permeation chromatography using conventional calibration), of greater than or equal to 15. All individual values and subranges of greater than or equal to 15 are included and disclosed herein. For example, in some embodiments, the first ethylene-based polymer component may have a molecular weight distribution (Mw,cc/Mn,cc) of greater than or equal to 16. In other embodiments, the first ethylene-based polymer component may have a molecular weight distribution (Mw,cc/Mn,cc) of greater than or equal to 18. In further embodiments, the first ethylene-based polymer component may have a molecular weight distribution (Mw,cc/Mn,cc) of greater than or equal to 19. In even further embodiments, the first ethylene-based polymer component may have a molecular weight distribution (Mw,cc/Mn,cc) of from 15 to 30, from 15 to 25, from 16 to 30, from 16 to 25, from 18 to 30, from 18 to 25, from 19 to 30, or from 19 to 25.

    [0021] In embodiments herein, the first ethylene-based polymer component may have a complex viscosity ratio, V0.1/V100, of greater than or equal to 10. All individual values and subranges of greater than or equal to 10 are included and disclosed herein. For example, in some embodiments, the first ethylene-based polymer component may have a complex viscosity ratio, V0.1/V100, of greater than or equal to 15, 20, 25, 28, or 30. In other embodiments, the first ethylene-based polymer component may have a complex viscosity ratio, V0.1/V100, of from 10 to 75, 15 to 75, 20 to 75, 25 to 75, 28 to 75, 30 to 75, 10 to 65, 15 to 65, 20 to 65, 25 to 65, 28 to 65, 30 to 65, 10 to 55, 15 to 55, 20 to 55, 25 to 55, 28 to 55, or 30 to 55.

    Second Ethylene-Based Polymer Component



    [0022] In embodiments herein, the second ethylene-based polymer component may be an ethylene homopolymer, an ethylene-based interpolymer, ethylene-based copolymer, ethylene/α-olefin interpolymer, or a heterogeneously branched ethylene-based interpolymer or copolymer. The comonomer may be an alpha-olefin as described herein. In some embodiments, the second ethylene-based polymer component is an ethylene-based interpolymer. In other embodiments, the second ethylene-based polymer component is a polyethylene homopolymer. In further embodiments, the second ethylene-based polymer component is a mixture of a polyethylene homopolymer and an ethylene/a-olefin interpolymer. The second ethylene-based polymer component may be formed using a Ziegler-Natta Catalyst, a single-site catalyst, or combinations thereof.

    [0023] In embodiments herein, the density of the second ethylene-based polymer component is from 0.940 to 0.970 g/cc. All individual values and subranges of 0.940 to 0.970 g/cc are included and disclosed herein. For example, in some embodiments, the density of the second ethylene-based polymer component is from 0.942 to 0.970 g/cc. In other embodiments, the density of the second ethylene-based polymer component is from 0.945 to 0.970 g/cc. In further embodiments, the density of the second ethylene-based polymer component is from 0.947 to 0.970 g/cc.

    [0024] In embodiments herein, the melt index, or I2.16, of the second ethylene-based polymer component is from 20 to 150 g/10 min. All individual values and subranges of from 20 to 150 g/10 min are included and disclosed herein. For example, in some embodiments, the melt index of the second ethylene-based polymer component is from 25 to 125 g/10 min. In other embodiments, the melt index of the second ethylene-based polymer component is from 30 to 100 g/10 min. In further embodiments, the melt index of the second ethylene-based polymer component is from 20 to 100 g/10 min, from 20 to 75 g/10 min, or from 25 to 75 g/10 min.

    Polyethylene Compositions



    [0025] In embodiments herein, the compositions may comprise from 7-70 wt.% of the first ethylene-based polymer component. All individual values and subranges of from 7-70 wt.% are included and disclosed herein. For example, in some embodiments, the composition may comprise from 7-65 wt.%, from 7-60 wt.%, from 7-50 wt.%, from 7-40 wt.%, from 7-35 wt.%, from 7-30 wt.%, from 7-25 wt.%, or from 7-20 wt.%, of the first ethylene-based polymer component. The composition may also comprise from 93-30 wt.% of the second ethylene-based polymer component. All individual values and subranges of 93-30 wt.% are included and disclosed herein. For example, in some embodiments, the composition may comprise from 93-40 wt.%, from 93-45 wt.%, from 93-50 wt.%, from 93-55 wt.%, from 93-60 wt.%, from 93-65 wt.%, from 93-70 wt.%, from 93-75 wt.%, or from 93-80 wt.%, of the second ethylene-based polymer component. The weight percentages are based on the sum weight of the first ethylene-based polymer component and the second ethylene-based polymer component.

    [0026] The composition has an overall density of from 0.945 - 0.960 g/cc. All individual values and subranges of 0.945 - 0.960 g/cc are included and disclosed herein. For example, in some embodiments, the composition may have an overall density of from 0.947 - 0.960 g/cc, 0.950 - 0.960 g/cc, 0.950 - 0.958 g/cc, or from 0.950 - 0.957 g/cc. The composition has an overall melt index, I2.16, of 10-70 g/10 min. All individual values and subranges of 10-70 g/10 min are included and disclosed herein. For example, in some embodiments, the composition may have an overall melt index of 10-65 g/10 min, 10-60 g/10 min, 10-55 g/10 min, 10-50 g/10 min, 10-45 g/10 min, 10-40 g/10 min, 10-35 g/10 min, 10-30 g/10 min, 10-25 g/10 min, or 10-23 g/10 min.

    [0027] The composition may have an overall melt index, I21.6, of from 100 to 615 g/10 min. All individual values and subranges of from 100 to 615 g/10 min are included and disclosed herein. For example, in some embodiments, the composition may have an overall melt index, I21.6, of from 125 to 615 g/10 min. In other embodiments, the composition may have an overall melt index, I21.6, of from 150 to 615 g/10 min, from 175 to 615 g/10 min, from 200 to 615 g/10 min, from 225 to 615 g/10 min, from 250 to 615 g/10 min, or from 275 to 615 g/10 min.

    [0028] In embodiments herein, the composition may have a weight average molecular weight (Mw,cc) of from 60,000 g/mol to 150,000 g/mol. All individual values and subranges of from 60,000 g/mol to 150,000 g/mol are included and disclosed herein. For example, in some embodiments, the composition may have a weight average molecular weight (Mw,cc) of from 60,000 g/mol to 125,000 g/mol. In other embodiments, the composition may have a weight average molecular weight (Mw,cc) of from 60,000 g/mol to 100,000 g/mol. In further embodiments, the composition may have a weight average molecular weight (Mw,cc) of from 60,000 g/mol to 90,000 g/mol. The weight average molecular weight may be determined by Gel Permeation Chromatography (GPC) using conventional calibration.

    [0029] In embodiments herein, the composition may have a viscosity at 100 rad/s and 190°C of greater than 2.0 × 102 to 8.0 × 102 Pa·s. All individual values and subranges of greater than 2.0 × 102 to 8.0 × 102 Pa·s are included and disclosed herein. For example, in some embodiments, the composition may have a viscosity at 100 rad/s and 190°C of from 2.0 × 102 to 7.75 × 102 Pa·s, 2.0 × 102 to 7.5 × 102 Pa·s, 2.0 × 102 to 7.0 × 102 Pa·s, 2.0 × 102 to 6.75 × 102 Pa·s, 2.0 × 102 to 6.5 × 102 Pa·s, 2.0 × 102 to 6.25 × 102 Pa·s, or 2.0 × 102 to 6.0 × 102 Pa·s. The viscosity may be determined as outlined below.

    [0030] In embodiments herein, the composition may comprise a Mw,cc of the first ethylene-based polymer component that is greater than the Mw,cc of the second ethylene-based polymer component. In some embodiments, the Mw,cc of the first ethylene-based polymer component is at least twice the Mw,cc of the second ethylene-based polymer component. In other embodiments, the Mw,cc of the first ethylene-based polymer component is at least three times the Mw,cc of the second ethylene-based polymer component. In further embodiments, the Mw,cc of the first ethylene-based polymer component is at least four times the Mw,cc of the second ethylene-based polymer component.

    [0031] In embodiments herein, the composition may contain one or more additives. Additives include, but are not limited to, processing aids, acid neutralizers, UV stabilizers, hydro peroxide decomposers, alkyl radical scavengers, hindered amine stabilizers, multifunctional stabilizers, phosphites, antioxidants, process stabilizers, metal de-activators, additives to improve oxidative or chlorine resistance, pigments or colorants, nucleating agents (e.g., metal salts of hexahydrophthalic acid (HHPA)), fatty acid stearates, fluoroelastomers, fillers, and combinations thereof. The composition may comprise from 0.001 to 10 wt.%, based on the weight of the composition, of the one or more additives.

    [0032] In embodiments herein, the composition can be made by a variety of methods. For example, it may be made by blending or mixing the first ethylene-based polymer component and the second ethylene-based polymer component together. Alternatively, the composition may be made in a single reactor or a multiple reactor configuration, where the multiple reactors may be arranged in series or parallel, and where each polymerization takes place in solution, in slurry, in the gas phase, or a combination of reaction systems (e.g. combination of slurry and gas phase reactor). In some embodiments, a dual reactor configuration is used where the polymer made in the first reactor can be either the first ethylene-based polymer component or the second ethylene-based polymer component. The polymer made in the second reactor may have a density and melt index that the overall density and melt index of the composition is met. Similar polymerization processes are described in, for example, WO 2004/101674A, which is incorporated herein by reference.

    [0033] In some embodiments herein, a method of manufacturing the compositions described herein may comprise blending a first ethylene-based polymer component, as described herein, with a second ethylene-based polymer component, as described herein, thereby producing a polyethylene composition. In other embodiments, a method of manufacturing the compositions described herein may comprise polymerizing a first ethylene-based polymer component, as described herein, in a reactor. polymerizing a second ethylene-based polymer component, as described herein, in a reactor, thereby producing a polyethylene composition. The two reactors may be operated in series. In some embodiments, the first ethylene-based polymer component is polymerized in a first reactor, and the second ethylene-based polymer component is polymerized in a second reactor. In other embodiments, the second ethylene-based polymer component is polymerized in a first reactor, and the first ethylene-based polymer component is polymerized in a second reactor.

    [0034] The compositions described herein can be used to manufacture a shaped/molded article, or one or more components of a shaped/molded article. Such articles may be single-layer or multi-layer articles, which may be obtained by suitable known conversion techniques, applying heat, pressure, or a combination thereof, to obtain the desired article. Examples of suitable conversion techniques may include, for example, blow-molding, co-extrusion blow-molding, injection molding, injection stretch blow molding, compression molding, extrusion, pultrusion, calendering and thermoforming. Shaped/molded articles may include, for example, closures, lids, bottles, blow molded articles, injection molded articles, compression molded articles, drip tapes and tubings, geomembranes, films, sheets, fibers, profiles and moldings.

    [0035] In embodiments herein, the compositions described herein may be particularly well-suited for use in manufacturing a shaped article or one or more components of a shaped article. In some embodiments, the compositions described herein may be particularly well-suited for use in manufacturing closures or lids. In other embodiments, the compositions described herein may be particularly well-suited for use in manufacturing single-piece closures or lids. In further embodiments, the compositions described herein may be particularly well-suited for use in manufacturing living hinge components.

    [0036] In some embodiments, a living hinge component may be formed by providing a molding unit having a mold according to processes known in the art and generally described in Plastic Injection Molding, Volume 1-Manufacturing Process Fundamentals by Douglas M. Bryce, introducing a composition as described herein into the mold, closing the molding unit, allowing the introduced composition to be maintained in the molding unit until the termination of a molding cycle, and opening the molding unit and removing the component from the mold. Without being bound by theory, it is believed that the compositions described herein exhibit good flowability (e.g., sufficiently high melt index) so as to fill the entire mold in order to fabricate a living hinge component.

    [0037] The living hinge component may have a thickness wherein the minimum thickness of the hinge portion is in the range of about 0.001 to 0.50 inches, about 0.005 to 0.025 inches, or about 0.01 to 0.014 inches. The living hinge component of the invention may have a ratio of the minimum thickness of the hinge portion to a maximum thickness of the hinged component that is less than or equal to 0.9, less than or equal to 0.5, or less than or equal to 0.3.

    [0038] In some embodiments, the component exhibits a hinge durability of greater than 800 cycles, as measured by the Hinge Durability Test. In other embodiments, the component exhibits a hinge durability of greater than 850 cycles, as measured by the Hinge Durability Test.

    [0039] In some embodiments, a living hinge component may be formed from the compositions described herein, and may include a filler, such as in amounts of approximately 0.1-80.0 wt.%. Suitable fillers for this purpose may include without limitation glass spheres, calcium carbonate, post-consumer recycle, glass fibers, talc, or any other organic or inorganic filler or combination thereof.

    [0040] In some embodiments, a living hinge component may be formed from the compositions described herein, and further comprise additional components, such as, polypropylene.

    TEST METHODS



    [0041] Unless otherwise stated, the following test methods are used. All test methods are current as of the filing date of this disclosure.

    Density



    [0042] Measurements are made according to ASTM D792, Method B.

    Melt Index



    [0043] Melt index, I2.16, for ethylene-based polymers is determined according to ASTM D1238 at 190°C, 2.16 kg. Melt Index, I21.6, for ethylene-based polymers is determined according to ASTM D1238 at 190°C, 21.6 kg.

    Gel Permeation Chromatography



    [0044] For the GPC techniques used herein (Conventional GPC and Light Scattering ("LS") GPC), a Triple Detector Gel Permeation Chromatography (3D-GPC or TDGPC) system is used. This system consists of a PolymerChar (Valencia, Spain) GPC-IR High Temperature Chromatograph, equipped with a Precision Detectors (Now Agilent Technologies) 2-angle laser light scattering (LS) detector Model 2040, an IR5 infra-red detector and 4-capillary viscometer detector from PolymerChar. Data collection is performed using PolymerChar "Instrument Control" software. The system is also equipped with an on-line solvent degassing device from Agilent Technologies (CA, USA).

    [0045] The eluent from the GPC column set flows through each detector arranged in series, in the following order: IR5 detector, LS detector, then the Viscometer detector. The systematic approach for the determination of multi-detector offsets is performed in a manner consistent with that published by Balke, Mourey, et al. (Mourey and Balke, Chromatography Polym., Chapter 12, (1992)) (Balke, Thitiratsakul, Lew, Cheung, Mourey, Chromatography Polym., Chapter 13, (1992)), optimizing triple detector log (MW and intrinsic viscosity) results from using a broad polyethylene standard, as outlined in the section on Light Scattering (LS) GPC below, in the paragraph following Equation (5).

    [0046] Four 20-micron mixed-pore-size packing ("Mixed A", Agilent Technologies) are used for the separation. The PolymerChar Autosampler oven compartment is operated at 160°C with low speed shaking for 3 hours, and the column compartment is operated at 150°C. The samples are prepared at a concentration of "2 milligrams per milliliter." The chromatographic solvent and the sample preparation solvent is 1,2,4-trichlorobenzene (TCB) containing "200 ppm of 2,6-di-tert-butyl-4methylphenol (BHT)." The solvent is sparged with nitrogen. The injection volume is 200 microliters. The flow rate through the GPC is set at 1 ml/minute. For this study, conventional GPC data and light scattering GPC data are recorded.

    [0047] For Conventional GPC, the IR5 detector ("measurement sensor") is used, and the GPC column set is calibrated by running 21 narrow molecular weight distribution polystyrene standards. The molecular weight (MW) of the standards range from 580 g/mol to 8,400,000 g/mol, and the standards are contained in 6 "cocktail" mixtures. Each standard mixture has at least a decade of separation between individual molecular weights. The standard mixtures are purchased from Polymer Laboratories (now Agilent Technologies). The polystyrene standards are prepared at "0.025 g in 50 mL of solvent" for molecular weights equal to, or greater than, 1,000,000 g/mol, and at "0.05 g in 50 mL of solvent" for molecular weights less than 1,000,000 g/mol. The polystyrene standards are dissolved at 80°C, with gentle agitation, for 30 minutes. The narrow standards mixtures are run first, and in order of decreasing highest molecular weight component, to minimize degradation. The polystyrene standard peak molecular weights are converted to polyethylene molecular weight using Equation (1) (as described in Williams and Ward, J. Polym. Sci., Polym. Letters, 6, 621 (1968)):

    where MW is the molecular weight of polyethylene (PE) or polystyrene (PS) as marked, and B is equal to 1.0. It is known to those of ordinary skill in the art that A may be in a range of about 0.38 to about 0.44 such that the A value yields 52,000 MWPE for Standard Reference Materials (SRM) 1475a. Use of this polyethylene calibration method to obtain molecular weight values, such as the molecular weight distribution (MWD or Mw/Mn), and related statistics, is defined here as the modified method of Williams and Ward. The number average molecular weight, the weight average molecular weight, and the z-average molecular weight are calculated from the following equations.





    where Mn,cc, Mw,cc, and Mz,cc are the number-, weight-, and z-average molecular weight obtained from the conventional calibration, respectively, wi is the weight fraction of the polyethylene molecules eluted at retention volume Vi. Mcc,i is the molecular weight of the polyethylene molecules eluted at retention volume Vi obtained using the conventional calibration (see Equation (1)).

    [0048] For the LS GPC, the Precision Detector PDI2040 detector Model 2040 15° angle is used. The molecular weight data is obtained in a manner consistent with that published by Zimm (Zimm, B.H., J. Chem. Phys., 16, 1099 (1948)) and Kratochvil (Kratochvil, P., Classical Light Scattering from Polymer Solutions, Elsevier, Oxford, NY (1987)). The overall injected concentration, used in the determination of the molecular weight, is obtained from the mass detector (IR5) area, and the mass detector constant, derived from a suitable linear polyethylene homopolymer, or one of the polyethylene standards of known weight-average molecular weight. The calculated molecular weights are obtained using a light scattering constant, derived from one or more of the polyethylene standards mentioned below, and a refractive index concentration coefficient, dn/dc, of 0.104. Generally, the mass detector response and the light scattering constant should be determined from a linear standard with a molecular weight in excess of about 50,000 g/mol. The viscometer calibration can be accomplished using the methods described by the manufacturer, or, alternatively, by using the published values of suitable linear standards, such as Standard Reference Materials (SRM) 1475a (available from National Institute of Standards and Technology (NIST)). The chromatographic concentrations are assumed low enough to eliminate addressing 2nd viral coefficient effects (concentration effects on molecular weight).

    [0049] With 3D-GPC, absolute weight-average molecular weight ("Mw,abs") and absolute z-average molecular weight ("Mz,abs") are determined using Equations (5) and (6) below, using the "peak area" method (after detector calibration relating areas to mass and mass - molecular weight product) for higher accuracy and precision. The "LS.Area" and the "Concentration. Area" are generated by the chromatograph/detectors combination.



    where Ci is the concentration of the polyethylene molecules in the eluant at the retention volume Vi, Mabs,i is the absolute molecular weight of the polyethylene molecules at the retention volume Vi, ∑LSi (LS.Area) is the total response of the light scattering, and the ∑Ci (Concentration.Area) is the total concentration.

    [0050] In the low molecular weight region of the GPC elution curve, the presence of a significant peak that is known to be caused by the presence of anti-oxidant or other additives, will cause an underestimation of the number average molecular weight (Mn) of the polymer sample, to give a overestimation of the sample polydispersity, defined as Mw/Mn, where Mw is the weight average molecular weight. The true polymer sample molecular weight distribution can therefore be calculated from the GPC elution by excluding this extra peak. This process is commonly described as the peak skim feature in data processing procedures in liquid chromatographic analyses. In this process, this additive peak is skimmed off from the GPC elution curve before the sample molecular weight calculation is performed from the GPC elution curve.

    Rheology - Viscosity



    [0051] The test sample in the rheology measurement is prepared from a compression molded plaque. A piece of aluminum foil is placed on a back plate, and a template or mold is placed on top of the back plate. Approximately 3.2 grams of resin is placed in the mold, and a second piece of aluminum foil is placed over the resin and mold. A second back plate is then placed on top of the aluminum foil. The total ensemble is put into a compression molding press and pressed for 6 min at 190°C under 25000 psi. The sample is then removed and laid on the counter to cool to room temperature. A 25 mm disk is stamped out of the compression-molded plaque. The thickness of this disk is approximately 3.0 mm.

    [0052] The rheology measurement to determine the viscosity at 0.1 rad/s and the viscosity at 100 rad/s is done in a nitrogen environment, at 190°C, and a strain of 10%. The stamped-out disk is placed between the two "25 mm" parallel plates located in an ARES-1 (Rheometrics SC) rheometer oven, which is preheated, for at least 30 minutes, at 190°C, and the gap of the "25 mm" parallel plates is slowly reduced to 2.0 mm. The sample is then allowed to remain for exactly 5 minutes at these conditions. The oven is then opened, the excess sample is carefully trimmed around the edge of the plates, and the oven is closed. The method has an additional five minute delay built in, to allow for temperature equilibrium. Then the viscosity at 0.1 rad/s and viscosity at 100 rad/s are measured via a small amplitude, oscillatory shear, according to an increasing frequency sweep from 0.1 to 100 rad/s. The complex viscosity at 0.1 rad/s (V0.1), the complex viscosity at 100 rad/s (V100), and the complex viscosity ratio (V0.1/V100) are calculated from these data.

    Living Hinge Durability



    [0053] The blends are generated in a 30 mm co-rotating, intermeshing Coperion Werner-Pfleiderer ZSK-30 twin screw extruder and then pelletized for the subsequent injection molding process. The ZSK-30 has ten barrel sections with an overall length of 960 mm and an L/D ratio of 32. The temperature is set at 80°C (zone 1 - feed), 160°C (zone 2), 180°C (zone 3), 185°C (zone 4), 195°C (zone 5), and 210°C (die).

    [0054] The blends prepared with the ZSK-30 are injection molded into bars using a lab scale injection molding equipment Morgan Press made by Morgan Industries Inc. (Long Beach, CA, USA). The geometry of the injection molded samples is shown in FIG. 1. The sample bars are 26mm in length, 5 mm in width and 1.7 mm in thickness. The sample bars have a hinge with a thickness of 0.2 mm. The injection direction is along the length direction. Both the barrel temperature and the nozzle temperature are set at 210°C. Mold temperature is set at room temperature. The ram pressure is set at 8000 psi and the pilot pressure is set at 60 psi. The clamp force is at 12 tons. In each injection cycle, the pressure holding time is 6 seconds, followed by 24 seconds for cooling and 30 seconds for releasing the mold, removing the sample out of the mold, closing the mold, and filling more materials into the barrel. The entire cycle time is 1 minute.

    [0055] The hinge durability is measured with an automatic pneumatic hinge durability tester. The 6 mm part of the sample bar is affixed to a stationary holder and the 20 mm part is rotated between -55° to +125° with the hinge as the center of rotation as shown in FIG. 2. The hinge durability tester has 10 sample holders and 10 sample bars from each resin are tested at the same time. The sample bars are initially held at the -55° position, rotated to the +125° position at a speed of about 0.1s/180°, held at the +125° position for 5 seconds, rotated back to the -55° position at a speed of about 0.1s/180°, held at the -55° position for 5 seconds to complete one cycle. The cycle at which a failure indicated by a complete breakage of the hinge is observed and recorded for each sample bar. All hinge durability testing is completed at 23°C and atmospheric pressure.

    EXAMPLES



    [0056] The embodiments described herein may be further illustrated by the following non-limiting examples.
    Table 1 - Inventive & Comparative Resin Properties
     Density (g/cc)Melt Index, I2.16 (g/10 min)Melt Index, I21.6 (g/10 min)I21.6/I2.16
    CONTINUUM™ DMDA-1250 NT7, available from The Dow Chemical Company (Midland, MI) 0.955 1.5 100 66.7
    CONTINUUM™ DGDA-2490 NT, available from The Dow Chemical Company (Midland, MI) 0.949 0.08 7 87.5
    CONTINUUM™ DGDA-2492 NT, available from The Dow Chemical Company (Midland, MI) 0.949 0.06 5.5 91.7
    UNIVAL™ DMDC-6143 NT 7, available from The Dow Chemical Company (Midland, MI) 0.952 0.13 14 107.7
    UNIVAL™ DMDA-6147 NT 7, available from The Dow Chemical Company (Midland, MI) 0.948 <0.15 10 >67
    UNIVAL™ DMDC-6150 NT7, available from The Dow Chemical Company (Midland, MI) 0.955 0.03 5.6 187
    DOW DMDA-8940 NT7, available from The Dow Chemical Company (Midland, MI) 0.951 44 840 19.1
    ELTEX® B4020N1331, available from Ineos Olefins & Polymers Europe 0.952 2.2 66 30
    Table 2 - Inventive & Comparative GPC Data
     Mw,ccMn,ccMz,ccMWD (Mw,cc/Mn,cc)Mw, absMz, abs
      g/mol g/mol g/mol   g/mol g/mol
    CONTINUUM™ DMDA-1250 NT7, available from The Dow Chemical Company (Midland, MI) 121,948 9,569 662,014 12.76 155,893 1,492,987
    CONTINUUM™ DGDA-2490 NT, available from The Dow Chemical Company (Midland, MI) 240,432 10,761 1,296,193 22.36 265,445 1,449,338
    CONTINUUM™ DGDA-2492 NT, available from The Dow Chemical Company (Midland, MI) 275,012 11,591 1,597,035 23.72 310,780 1,910,739
    UNIVAL™ DMDC-6143 NT7, available from The Dow Chemical Company (Midland, MI) 236,116 11,442 2,508,374 20.64 217,121 1,832,644
    UNIVAL™ DMDA-6147 NT7, available from The Dow Chemical Company (Midland, MI) 255,547 12,400 2,367,852 20.61 237,080 1,760,612
    UNIVAL™ DMDC-6150 NT7, available from The Dow Chemical Company (Midland, MI) 295,399 13,546 2,615,825 21.85 275,389 1,877,697
    DOW DMDA-8940 NT7, available from The Dow Chemical Company (Midland, MI) 45,889 9,448 200,227 4.86 61,046 1,891,889
    ELTEX® B4020N1331, available from Ineos Olefins & Polymers Europe 110,972 15,640 534,665 7.10 184,149 2,813,559
    Table 3 - Inventive & Comparative Complex Viscosity Data
     V0.1V100V0.1/V100
     Pa·sPa·s 
    CONTINUUM™ DMDA-1250 NT7, available from The Dow Chemical Company (Midland, MI) 7,862 937 8.4
    CONTINUUM™ DGDA-2490 NT, available from The Dow Chemical Company (Midland, MI) 83,791 2,644 31.7
    CONTINUUM™ DGDA-2492 NT, available from The Dow Chemical Company (Midland, MI) 138,640 2,742 50.6
    UNIVAL™ DMDC-6143 NT7, available from The Dow Chemical Company (Midland, MI) 55,342 1,735 31.9
    UNIVAL™ DMDA-6147 NT7, available from The Dow Chemical Company (Midland, MI) 80,989 2,036 39.8
    UNIVAL™ DMDC-6150 NT7, available from The Dow Chemical Company (Midland, MI) 124,690 2,597 48.0
    DOW DMDA-8940 NT7, available from The Dow Chemical Company (Midland, MI) 176 134 1.3
    ELTEX® B4020N1331, available from Ineos Olefins & Polymers Europe 4,336 1,025 4.2

    Inventive & Comparative Compositions



    [0057] The inventive and comparative compositions were prepared as outlined above for the Living Hinge Test. The compositions were generated in a 30 mm co-rotating, intermeshing Coperion Werner-Pfleiderer ZSK-30 twin screw extruder and then pelletized for the subsequent injection molding process. The ZSK-30 has ten barrel sections with an overall length of 960 mm and an L/D ratio of 32. The temperature is set at 80°C (zone 1 - feed), 160°C (zone 2), 180°C (zone 3), 185°C (zone 4), 195°C (zone 5), and 210°C (die). Tables 4 and 5 below further provide additional description of the inventive and comparative compositions.

    [0058] The blends prepared with the ZSK-30 are injection molded into bars using a lab scale injection molding equipment Morgan Press made by Morgan Industries Inc. (Long Beach, CA, USA). The geometry of the injection molded samples is shown in FIG. 1. The sample bars are 26mm in length, 5 mm in width and 1.7 mm in thickness. The sample bars have a hinge with a thickness of 0.2 mm. The injection direction is along the length direction. Both the barrel temperature and the nozzle temperature are set at 210°C. Mold temperature is set at room temperature. The ram pressure is set at 8000 psi and the pilot pressure is set at 60 psi. The clamp force is at 12 tons. In each injection cycle, the pressure holding time is 6 seconds, followed by 24 seconds for cooling and 30 seconds for releasing the mold, removing the sample out of the mold, closing the mold, and filling more materials into the barrel. The entire cycle time is 1 minute. Table 6 and 7 provides test results for various properties of the inventive and comparative compositions.
    Table 4 - Inventive Compositions
    DescriptionFirst ComponentSecond Component
    Inv. 1 10 wt.% DGDA-2490 90 wt.% DMDA-8940
    Inv. 2 15 wt.% DGDA-2490 85 wt.% DMDA-8940
    Inv. 3 15 wt.% DGDA-2492 85 wt.% DMDA-8940
    Inv. 4 10 wt.% DMDC-6143 90 wt.% DMDA-8940
    Inv. 5 15 wt.% DMDC-6143 85 wt.% DMDA-8940
    Inv. 6 10 wt.% DMDA-6147 90 wt.% DMDA-8940
    Inv. 7 15 wt.% DMDA-6147 85 wt.% DMDA-8940
    Inv. 8 10 wt.% DMDA-6150 90 wt.% DMDA-8940
    Inv. 9 15 wt.% DMDA-6150 85 wt.% DMDA-8940
    Table 5 - Comparative Compositions
    DescriptionFirst ComponentSecond Component
    Comp. A   100 wt.% DMDA-8940
    Comp. B 25 wt.% DMDC-1250 75 wt.% DMDA-8940
    Comp. C 5 wt.% DMDA-6147 95 wt.% DMDA-8940
    Comp. D 5 wt.% DMDA-6150 95 wt.% DMDA-8940
    Comp. E 5 wt.% B4020N1331 95 wt.% DMDA-8940
    Comp. F 10 wt.% B4020N1331 90 wt.% DMDA-8940
    Comp. G 15 wt.% B4020N1331 85 wt.% DMDA-8940
    Table 6 - Inventive & Comparative Composition Properties
     DensityI2.16I21.6
     g/ccg/10 ming/10 min
    Inv. 1 0.954 19.4 603
    Inv. 2 0.9543 13.7 511
    Inv. 3 0.9539 12.8 482
    Inv. 4 0.9522 21.4 576
    Inv. 5 0.9538 15.6 474
    Inv. 6 0.9533 19.1 539
    Inv. 7 0.9533 13.9 432
    Inv. 8 0.9543 17.9 491
    Inv. 9 0.9546 11.4 398
           
    Comp. A 0.951 44.0 840
    Comp. B 0.9545 17.9 600
    Comp. C 0.9534 27.3 690
    Comp. D 0.9544 27.5 718
    Comp. E 0.9542 34.2 750
    Comp. F 0.9544 26.7 683
    Comp. G 0.9543 24.1 625
    Table 6 - Inventive & Comparative Composition Properties Cont'd
     Mn,ccMw,ccMz,ccMWD (Mw,cc/Mn,cc)Mw,absMz,abs
     g/molg/molg/mol g/molg/mol
    Inv. 1 9,985 65,952 525,411 6.61 86,512 1,427,361
    Inv. 2 9,856 77,406 689,059 7.85 99,949 1,558,860
    Inv. 3 9,870 75,922 754,157 7.69 97,505 1,774,513
    Inv. 4 9,199 61,482 585,173 6.68 81,905 2,130,158
    Inv. 5 10,351 73,725 1,092,265 7.12 94,326 2,661,331
    Inv. 6 10,956 65,615 599,371 5.99 105,353 3,320,005
    Inv. 7 10,810 69,129 661,563 6.39 110,573 3,397,945
    Inv. 8 10,472 68,536 938,678 6.54 95,454 3,232,529
    Inv. 9 9,767 82,707 1,259,138 8.47 106,473 2,629,063
                 
    Comp. A 9,448 45,889 200,227 4.86 61,046 1,891,889
    Comp. B 9,603 65,084 407,781 6.78 83,337 1,281,362
    Comp. C 10,913 58,575 464,183 5.37 100,547 3,570,057
    Comp. D 9,529 56,611 509,921 5.94 77,929 2,500,915
    Comp. E 10,370 47,945 197,425 4.62 62,542 1,409,107
    Comp. F 9,654 52,689 263,766 5.46 71,286 1,799,036
    Comp. G 9,882 54,593 268,721 5.52 75,452 1,881,762
    Table 6 - Inventive & Comparative Composition Properties Cont'd
     V0.1V100V0.1/V100
     Pa·sPa·s 
    Inv. 1 881 243 3.6
    Inv. 2 1,352 280 4.8
    Inv. 3 1,504 277 5.4
    Inv. 4 634 209 3.0
    Inv. 5 1,042 252 4.1
    Inv. 6 703 214 3.3
    Inv. 7 1,243 254 4.9
    Inv. 8 912 229 4.0
    Inv. 9 1,843 294 6.3
           
    Comp. A 176 134 1.3
    Comp. B 693 251 2.8
    Comp. C 449 186 2.4
    Comp. D 412 162 2.5
    Comp. E 248 171 1.4
    Comp. F 332 199 1.7
    Comp. G 339 191 1.8


    [0059] The measured durability of living hinges fabricated from the inventive and comparative resins are reported in Tables 6. Hinge sample 1 is made from inventive resin 1. Hinge sample 2 is made from inventive resin 2. Hinge sample 3 is made from inventive resin 3. Hinge sample 4 is made from inventive resin 4. Hinge sample 5 is made from inventive resin 5. Hinge sample 6 is made from inventive resin 6. Hinge sample 7 is made from inventive resin 7. Hinge sample 8 is made from inventive resin 8. Hinge sample 9 is made from inventive resin 9. Hinge sample A is made from comparative resin A. Hinge sample B is made from comparative resin B. Hinge sample C is made from comparative resin C. Hinge sample D is made from comparative resin D. Hinge sample E is made from comparative resin E. Hinge sample F is made from comparative resin F. Hinge sample G is made from comparative resin G. All hinge samples are made according to the procedure described in the Living Hinge Durability test method.
    Table 7 - Living Hinge Durability Test Results
     Number of Cycles to Break
    Hinge 1 1422
    Hinge 2 2137
    Hinge 3 2130
    Hinge 4 891
    Hinge 5 1353
    Hinge 6 897
    Hinge 7 1284
    Hinge 8 1305
    Hinge 9 2075
       
    Hinge A 331
    Hinge B 1323
    Hinge C 583
    Hinge D 731
    Hinge E 546
    Hinge F 680
    Hinge G 936


    [0060] The results show that the inventive compositions have good processability, and furthermore, living hinges fabricated from the inventive compositions are more durable (i.e., have a high number of cycles to break) than those fabricated from the comparative compositions at the same blending ratio.

    [0061] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."


    Claims

    1. A polyethylene composition suitable for use in a living hinge component, the composition comprising:

    a first ethylene-based polymer component, wherein the first ethylene-based polymer component has a density of from 0.940 g/cc to less than 0.960 g/cc, a melt index, I2.16, of less than 0.5 g/10 min, and a weight average molecular weight as measured by gel permeation chromatography measured according to the method described in the description, Mw,cc, of greater than or equal to 200,000 g/mol; and

    a second ethylene-based polymer component, wherein the second ethylene-based polymer component has a density from 0.940 g/cc to less than 0.970 g/cc and a melt index, I2.16, of 20 - 150 g/10 min;

    wherein the composition has an overall density of from 0.945 g/cc to 0.960 g/cc and an overall melt index, I2.16, of from 10 g/10 min to 70 g/10 min.


     
    2. The composition of any of the previous claims, wherein the composition comprises from 7 wt.% to 20 wt.% of the first ethylene-based polymer component, and from 80 wt.% to about 93 wt.% of the second ethylene-based polymer component.
     
    3. The composition of any of the previous claims, wherein the first ethylene-based polymer component has a molecular weight distribution, Mw,cc/Mn,cc, of greater than or equal to 15, wherein the Mn,cc is the number average molecular weight as measured by gel permeation chromatography measured according to the method described in the description.
     
    4. The composition of any of the previous claims, wherein the first ethylene-based polymer component has a complex viscosity ratio, V0.1/V100, of greater than or equal to 10, wherein the complex viscosity ratio is measured according to the method described in the description.
     
    5. A living hinge component comprising a polyethylene composition, the composition comprising:

    a first ethylene-based polymer component, wherein the first ethylene-based polymer component has a density of from 0.940 g/cc to less than 0.960 g/cc, a melt index, I2.16, of less than 0.5 g/10 min, and a weight average molecular weight, Mw,cc, as measured by gel permeation chromatography measured according to the method described in the description of greater than or equal to 200,000 g/mol; and

    a second ethylene-based polymer component, wherein the second ethylene-based polymer component has a density from 0.940 g/cc to less than 0.970 g/cc and a melt index, I2.16, of 20 - 150 g/10 min;

    wherein the composition has an overall density of from 0.945 g/cc to 0.960 g/cc and an overall melt index, I2.16, of from 10 g/10 min to 70 g/10 min.


     
    6. The living hinge component of claim 5, wherein the composition comprises from 7 wt.% to 20 wt.% of the first ethylene-based polymer component, and from 80 wt.% to about 93 wt.% of the second ethylene-based polymer component.
     
    7. The living hinge component of claim 5, wherein the first ethylene-based polymer component has a molecular weight distribution, Mw,cc/Mn,cc, of greater than or equal to 15, wherein the Mn,cc is the number average molecular weight as measured by gel permeation chromatography measured according to the method described in the description.
     
    8. The living hinge component of claim 5, wherein the first ethylene-based polymer component has a complex viscosity ratio, V0.1/V100, of greater than or equal to 10, wherein the complex viscosity ratio is measured according to the method described in the description.
     
    9. The living hinge component of claim 5, wherein the component exhibits a hinge durability of greater than 800 cycles, as measured by the Hinge Durability Test described in the description.
     


    Ansprüche

    1. Eine Polyethylenzusammensetzung, die zur Verwendung in einer Filmscharnierkomponente geeignet ist, wobei die Zusammensetzung Folgendes beinhaltet:

    eine erste Polymerkomponente auf Ethylenbasis, wobei die erste Polymerkomponente auf Ethylenbasis eine Dichte von 0,940 g/cm3 bis weniger als 0,960 g/cm3, einen Schmelzindex, I2,16, von weniger als 0,5 g/10 min und ein gewichtsmittleres Molekulargewicht, Mw,cc, von größer als oder gleich 200 000 g/mol aufweist, wie gemessen durch Gelpermeationschromatographie, gemessen gemäß dem in der Beschreibung beschriebenen Verfahren; und

    eine zweite Polymerkomponente auf Ethylenbasis, wobei die zweite Polymerkomponente auf Ethylenbasis eine Dichte von 0,940 g/cm3 bis weniger als 0,970 g/cm3 und einen Schmelzindex, I2,16, von 20-150 g/10 min aufweist;

    wobei die Zusammensetzung eine Gesamtdichte von 0,945 g/cm3 bis 0,960 g/cm3 und einen Gesamtschmelzindex, I2,16, von 10 g/10 min bis 70 g/10 min aufweist.


     
    2. Zusammensetzung gemäß einem der vorhergehenden Ansprüche, wobei die Zusammensetzung zu 7 Gew.-% bis 20 Gew.-% die erste Polymerkomponente auf Ethylenbasis und zu 80 Gew.-% bis etwa 93 Gew.-% die zweite Polymerkomponente auf Ethylenbasis beinhaltet.
     
    3. Zusammensetzung gemäß einem der vorhergehenden Ansprüche, wobei die erste Polymerkomponente auf Ethylenbasis eine Molekulargewichtsverteilung, Mw,cc/Mn,cc, von größer als oder gleich 15 aufweist, wobei Mn,cc das zahlenmittlere Molekulargewicht ist, wie gemessen durch Gelpermeationschromatographie, gemessen gemäß dem in der Beschreibung beschriebenen Verfahren.
     
    4. Zusammensetzung gemäß einem der vorhergehenden Ansprüche, wobei die erste Polymerkomponente auf Ethylenbasis ein komplexes Viskositätsverhältnis, V0,1/V100, von größer als oder gleich 10 aufweist, wobei das komplexe Viskositätsverhältnis gemäß dem in der Beschreibung beschriebenen Verfahren gemessen wird.
     
    5. Eine Filmscharnierkomponente, die eine Polyethylenzusammensetzung beinhaltet, wobei die Zusammensetzung Folgendes beinhaltet:

    eine erste Polymerkomponente auf Ethylenbasis, wobei die erste Polymerkomponente auf Ethylenbasis eine Dichte von 0,940 g/cm3 bis weniger als 0,960 g/cm3, einen Schmelzindex, I2,16, von weniger als 0,5 g/10 min und ein gewichtsmittleres Molekulargewicht, Mw,cc, von größer als oder gleich 200 000 g/mol aufweist, wie gemessen durch Gelpermeationschromatographie, gemessen gemäß dem in der Beschreibung beschriebenen Verfahren; und

    eine zweite Polymerkomponente auf Ethylenbasis, wobei die zweite Polymerkomponente auf Ethylenbasis eine Dichte von 0,940 g/cm3 bis weniger als 0,970 g/cm3 und einen Schmelzindex, I2,16, von 20-150 g/10 min aufweist;

    wobei die Zusammensetzung eine Gesamtdichte von 0,945 g/cm3 bis 0,960 g/cm3 und einen Gesamtschmelzindex, I2,16, von 10 g/10 min bis 70 g/10 min aufweist.


     
    6. Filmscharnierkomponente gemäß Anspruch 5, wobei die Zusammensetzung zu 7 Gew.-% bis 20 Gew.-% die erste Polymerkomponente auf Ethylenbasis und zu 80 Gew.-% bis etwa 93 Gew.-% die zweite Polymerkomponente auf Ethylenbasis beinhaltet.
     
    7. Filmscharnierkomponente gemäß Anspruch 5, wobei die erste Polymerkomponente auf Ethylenbasis eine Molekulargewichtsverteilung, Mw,cc /Mn,cc, von größer als oder gleich 15 aufweist, wobei Mn,cc das zahlenmittlere Molekulargewicht ist, wie gemessen durch Gelpermeationschromatographie, gemessen gemäß dem in der Beschreibung beschriebenen Verfahren.
     
    8. Filmscharnierkomponente gemäß Anspruch 5, wobei die erste Polymerkomponente auf Ethylenbasis ein komplexes Viskositätsverhältnis, V0,1/V100, von größer als oder gleich 10 aufweist, wobei das komplexe Viskositätsverhältnis gemäß dem in der Beschreibung beschriebenen Verfahren gemessen wird.
     
    9. Filmscharnierkomponente gemäß Anspruch 5, wobei die Komponente eine Scharnierhaltbarkeit von mehr als 800 Zyklen vorweist, wie durch den in der Beschreibung beschriebenen Scharnierhaltbarkeitstest gemessen.
     


    Revendications

    1. Une composition de polyéthylène convenant pour être utilisée dans un composant de charnière vivante, la composition comprenant :

    un premier composant polymère à base d'éthylène, le premier composant polymère à base d'éthylène ayant une masse volumique allant de 0,940 g/cm3 à moins de 0,960 g/cm3, un indice de fluidité à chaud, I2,16, de moins de 0,5 g/10 min, et une masse moléculaire moyenne en poids telle que mesurée par chromatographie par perméation sur gel mesurée selon la méthode décrite dans la description, Mw,cc, supérieure ou égale à 200 000 g/mol ; et

    un deuxième composant polymère à base d'éthylène, le deuxième composant polymère à base d'éthylène ayant une masse volumique allant de 0,940 g/cm3 à moins de 0,970 g/cm3 et un indice de fluidité à chaud, I2,16, de 20 à 150 g/10 min ;

    la composition ayant une masse volumique globale allant de 0,945 g/cm3 à 0,960 g/cm3 et un indice de fluidité à chaud global, I2,16, allant de 10 g/10 min à 70 g/10 min.


     
    2. La composition de n'importe lesquelles des revendications précédentes, la composition comprenant de 7 % en poids à 20 % en poids du premier composant polymère à base d'éthylène, et de 80 % en poids à environ 93 % en poids du deuxième composant polymère à base d'éthylène.
     
    3. La composition de n'importe lesquelles des revendications précédentes, dans laquelle le premier composant polymère à base d'éthylène a une distribution des masses moléculaires, Mw,cc/Mn,cc, supérieure ou égale à 15, la Mn,cc étant la masse moléculaire moyenne en nombre telle que mesurée par chromatographie par perméation sur gel mesurée selon la méthode décrite dans la description.
     
    4. La composition de n'importe lesquelles des revendications précédentes, dans laquelle le premier composant polymère à base d'éthylène a un rapport de viscosité complexe, V0,1/V100, supérieur ou égal à 10, le rapport de viscosité complexe étant mesuré selon la méthode décrite dans la description.
     
    5. Un composant de charnière vivante comprenant une composition de polyéthylène, la composition comprenant :

    un premier composant polymère à base d'éthylène, le premier composant polymère à base d'éthylène ayant une masse volumique allant de 0,940 g/cm3 à moins de 0,960 g/cm3, un indice de fluidité à chaud, I2,16, de moins de 0,5 g/10 min, et une masse moléculaire moyenne en poids, Mw,cc, telle que mesurée par chromatographie par perméation sur gel mesurée selon la méthode décrite dans la description supérieure ou égale à 200 000 g/mol ; et

    un deuxième composant polymère à base d'éthylène, le deuxième composant polymère à base d'éthylène ayant une masse volumique allant de 0,940 g/cm3 à moins de 0,970 g/cm3 et un indice de fluidité à chaud, I2,16, de 20 à 150 g/10 min ;

    la composition ayant une masse volumique globale allant de 0,945 g/cm3 à 0,960 g/cm3 et un indice de fluidité à chaud global, I2,16, allant de 10 g/10 min à 70 g/10 min.


     
    6. Le composant de charnière vivante de la revendication 5, dans lequel la composition comprend de 7 % en poids à 20 % en poids du premier composant polymère à base d'éthylène, et de 80 % en poids à environ 93 % en poids du deuxième composant polymère à base d'éthylène.
     
    7. Le composant de charnière vivante de la revendication 5, dans lequel le premier composant polymère à base d'éthylène a une distribution des masses moléculaires, Mw,cc/Mn,cc, supérieure ou égale à 15, la Mn,cc est la masse moléculaire moyenne en nombre telle que mesurée par chromatographie par perméation sur gel mesurée selon la méthode décrite dans la description.
     
    8. Le composant de charnière vivante de la revendication 5, dans lequel le premier composant polymère à base d'éthylène a un rapport de viscosité complexe, V0,1/V100, supérieur ou égal à 10, le rapport de viscosité complexe étant mesuré selon la méthode décrite dans la description.
     
    9. Le composant de charnière vivante de la revendication 5, le composant présentant une durabilité de charnière supérieure à 800 cycles, telle que mesurée par le test de durabilité de charnière décrit dans la description.
     




    Drawing











    Cited references

    REFERENCES CITED IN THE DESCRIPTION



    This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.

    Patent documents cited in the description




    Non-patent literature cited in the description