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Conventional multi-material multi-layer flexible packaging offers excellent properties. However, it has recycling challenges, necessitating a shift to mono-material multi-layer flexible packaging for example all-polyethylene (PE) packaging which can be tailored through various synthesis and processing methods for different layers. In this work, we study how the key molecular properties (number-average molecular weight (M n), weight-average molecular weight (M w ), molecular weight distribution (MWD), comonomer content (short chain branching)) and machine direction orientation (MDO) process draw ratio (MDX) influence the final morphology and mechanical properties of MDO-PE films which are intended as the outer layer of mono-material all-polyethylene multi-layer flexible packaging. Five PE grades and various blends were extruded and blown into films. Selected blown films were machine direction oriented to obtain the final MDO-PE films. Furthermore, one selected PE blown film was processed at different MDO process draw ratios while keeping other process parameters constant. From the molecular properties point of view, the higher molecular weight fractions provide a higher possibility for uniform stretching whereas lower molecular weight fractions provide a higher natural draw ratio and therefore higher modulus and stiffness enhancement. Further, the results show that increasing MDO process draw ratio leads to more fibrillation and increased crystallinity. Consequently, the tensile modulus and stiffness at the higher draw ratios increase as well and are comparable to conventionally used polymers in outer layers of multilayer flexible packaging. Thus, this work demonstrates that MDO-PE films with enhanced modulus can provide sufficient stiffness for the design of outer layer of mono-material multi-layer all-PE packaging which presents higher potential for mechanical recyclability. [ABSTRACT FROM AUTHOR]

We develop a method for efficient prediction of linear and nonlinear rheology of polydisperse polymers by judicious selection of a small number of representative polymer molecules from the large ensemble of chains comprising the molecular weight and branching distribution. Specifically, we use a numerical inversion of the double reptation model to select five or six representative molecular species to optimally fit the linear rheology of commercial polymers and then use the regressed parameters to compute the nonlinear rheology via the Rolie-double-poly (RDP) model. The method is tested for several model systems, namely, two polydisperse linear polystyrene (PS) samples described in Shivokhin et al. [Polym. Eng. Sci. 56, 1012–1020 (2016)] and Münstedt [J. Rheol. 24, 847–867 (1980)], a commercial linear low density polyethylene (LLDPE), and a low density polyethylene (LDPE) whose rheological properties are measured in the current study. For the linear polymers including the PS samples and the LLDPE, the predictions of the "representative" RDP model of the start-up extensional rheology are comparable to those of the "full" RDP model based on all the species drawn from the gas permeation chromatography characterization. The method then successfully predicts the linear rheology of blends of LLDPE and LDPE using the same representative molecules found by fitting each of the pure polymers. Further fitting the extensional rheology of the LDPE requires using the "priorities" q i and stretch relaxation times τ s , i of the representative molecules as adjustable parameters, whose values are then held fixed when predicting the extensional rheology of blends of the LDPE with the LLDPE roughly as successfully as does branch-on-branch model. The reduction in the number of representative polymer species offers new opportunities for faster simulations of flowing polymers, as well as for the prediction of segmental orientation to be used in the modeling of flow-induced crystallization. [ABSTRACT FROM AUTHOR]