Ethylene-Based Interpolymers and Processes to Make the Same

Abstract

Ethylene-based interpolymers, e.g., ethylene-acrylic acid copolymers, are made by a process comprising the steps of: A. Injecting a first feed comprising a chain transfer agent system (CTA system) and ethylene into a first autoclave reactor zone to produce a first zone reaction product, the CTA system of the first reactor zone having a transfer activity Z1; and B. (1) Transferring at least part of the first zone reaction product to a second reactor zone selected from a second autoclave reactor zone or a tubular reactor zone, and (2) at least one of transferring or freshly injecting a feed comprising a CTA system into the second reactor zone to produce a second zone reaction product, the CTA system of the second reactor zone having a transfer activity of Z2; and with the proviso that the ratio of Z1:Z2 is greater than 1. The comonomer comprises at least one carboxylic acid group or an anhydride group.

1 - 15 . (canceled) 
     
     
         16 . An ethylene-based interpolymer comprising at least one comonomer that comprises at least one ethylenic unsaturation and at least one carbonyl group, and wherein the interpolymer comprises at least one the following properties:
 A. An average small gel count per 50,000 square inches (in 2 ) of less than or equal to 600; and   B. An average micro gel count per 50,000 in 2  of less than or equal to 3,500.   
     
     
         17 . The ethylene-based interpolymer of  claim 16  having a percent by weight of acid comonomer units in the polymer chain from 2 to 30. 
     
     
         18 . The ethylene-based interpolymer of  claim 16  having a molecular weight distribution (MWD, Mw/Mn) from 3 to 20. 
     
     
         19 . The ethylene-based interpolymer of  claim 17  having a molecular weight distribution (MWD, Mw/Mn) from 3 to 20. 
     
     
         20 . The ethylene-based interpolymer of  claim 16  wherein the ethylenic unsaturation of the comonomer is conjugated with the carbonyl group. 
     
     
         21 . The ethylene-based interpolymer of  claim 16  wherein the comonomer is at least one of an ethylenically unsaturated carboxylic acid, anhydride, or ester or its salt. 
     
     
         22 . The ethylene-based interpolymer of  claim 16  wherein the comonomer is acrylic acid or methacrylic acid. 
     
     
         23 . The ethylene-based interpolymer of  claim 16  wherein the average small gel count per 50,000 square inches (in 2 ) of less than or equal to 300. 
     
     
         24 . The ethylene-based interpolymer of  claim 16  wherein the average micro gel count per 50,000 in 2  of less than or equal to 1,500. 
     
     
         25 . The ethylene-based interpolymer of  claim 16  wherein the percent by weight of acid comonomer units in the interpolymer chain is from 4 to 15. 
     
     
         26 . The ethylene-based interpolymer of  claim 16  wherein the molecular weight distribution (MWD, Mw/Mn) from 5 to 12. 
     
     
         27 . The ethylene-based interpolymer of  claim 16  comprising greater than, or equal to, 1 weight percent of the comonomer based on the weight of the interpolymer. 
     
     
         28 . A composition comprising the ethylene-based interpolymer of  claim 16 . 
     
     
         29 . The composition of  claim 28  comprising at least one other ethylene-based polymer. 
     
     
         30 . An article comprising the composition of  claim 29 . 
     
     
         31 . A film comprising the composition of  claim 29 .