Thin walled polyethylene container

Abstract

Thin walled polyethylene containers are suitable for the packaging of foods such as cottage cheese, ricotta cheese and ice cream. The containers have a higher softening point (which permits the containers to be “hot filled”) and high impact strength at low temperature (which is useful when a container of ice cream is dropped).

Description

FIELD OF THE INVENTION

[0001] This invention relates to thin walled polyethylene containers. The containers are useful for packaging foods such as cottage cheese and ice cream.

BACKGROUND OF THE INVENTION

[0002] Plastic food containers are ubiquitous items of commerce. Ideally, these containers should have thin walls (preferably from about 0.35 millimeters to 1.30 millimeters thick) in order to reduce the amount of plastic used to produce the container. However, the containers must also have strength at high temperatures (for example, to permit a container to be filled with ricotta cheese at temperatures over 80° C.) and at low temperatures (so as to withstand the impact when a filled ice cream container is dropped). Such “thinwalled” containers are typically prepared by injection molding.

[0003] Injection molding equipment is widely available and is well described in the literature. The machinery is highly productive, with molding cycle times often being measured in seconds. These machines are also very expensive so there is a need to maximize productivity (i.e. minimize cycle times) in order to control overall production costs. Productivity may be influenced by the choice of plastic resin used in the process. In particular, a resin which flows well is desirable to reduce cycle times.

[0004] Flow properties are typically influenced by molecular weight (with low molecular weight resin having superior flow properties in comparison to high molecular weight resin) and molecular weight distribution (with narrow molecular weight resins generally producing molded parts with reduced warpage in comparison to broad molecular weight distribution resins). Copolymer resins of similar molecular weight and molecular weight distribution generally have higher hexane extractables levels than homopolymer resins, making them less satisfactory for food applications.

[0005] The strength of the finished product over a range of temperatures is also important. The strength of a finished product may often be increased by increasing the molecular weight of the resin used to prepare it, but this is done at the expense of machine productivity. Similarly, the use of a copolymer resin will often improve the impact strength and flexibility of a product in comparison to the use of homopolymer, but at the expense of extractables content. Thus, a suitable food container which is made at high “machine productivity” yet also demonstrates good strength properties at high and low temperatures would be a useful addition to the art.

SUMMARY OF THE INVENTION

[0006] The present invention provides a container having a nominal volume of from 100 mL to 12 L which is prepared by injection molding of ethylene copolymer resin, said container having a Vicat softening point of greater than 121° C. and an average test drop height point of greater than 2.5 feet as determined by ASTM D5276 wherein said ethylene copolymer resin is characterized by having:

[0007] i) a density of from 0.950 g/cc to 0.955 g/cc;

[0008] ii) a viscosity at 100,000 s−1 and 280° C. of less than 3.5 Pascal seconds;

[0009] iii) a molecular weight distribution, Mw/Mn of from 2.2 to 2.8; and

[0010] iv) a hexane extractables content of less than 0.5 weight %.

[0011] Preferred containers also have a total impact energy required for base failure of greater than 0.2 foot-pounds at −20° C. as determined by Instrumented Impact Testing according to ASTM D3763 (with an instrument sold under the tradename “INSTRON-DYNATUP”).

DETAILED DESCRIPTION

[0012] We have discovered that thinwalled polyethylene containers having a Vicat softening point of greater than 121° C. and an average test drop height of greater than 2.5 feet may be prepared from a linear polyethylene copolymer resin having all of the following essential characteristics:

[0013] 1) a density of from 0.950 to 0.955 g/cc;

[0014] 2) a melt index I2, of from 30 to 100 g/10 min as measured by ASTM D1238 at 190° C.;

[0015] 3) a molecular weight distribution (Mw/Mn) of from 2.2 to 2.8;

[0016] 4) an apparent viscosity at 100,000 s−1 and 280° C. of less than 3.5 Pascal seconds; and

[0017] 5) a hexane extractables content of less than 0.5 weight %. Each of these characteristics is described below.

[0018] The density of a polyethylene copolymer is influenced by the molecular structure of the copolymer. “Linear” homopolymers of ethylene are rigid molecules that solidify as crystalline resins. Linear ethylene resins which also have a narrow molecular weight distribution (Mw/Mn, discussed below) are further characterized by having sharp (distinct) melting points, which is desirable for injection molding processes. However, the impact strength of such resins (especially at low temperatures) is poor. The density of a linear ethylene homopolymer having a narrow molecular weight distribution is generally greater than 0.958 grams per cubic centimeter (“g/cc”).

[0019] The density of a linear ethylene polymer may be reduced by incorporating a comonomer (such as butene, hexene, or octene) into the polymer structure. The comonomers produce “branches” which inhibit crystal packing and the resulting copolymers generally display improved impact strengths in comparison to homopolymers. For example, flexible polyethylene films (not a part of this invention) are typically made from copolymers having more than 8 mole % comonomer and a density from about 0.905 to 0.935 g/cc.

[0020] The copolymer used in this invention contains a comparatively small but critical amount of comonomer. The linear ethylene copolymers must have a density of from 0.950 to 0.955 g/cc. This very specific and narrow density range is essential in order to obtain high machine productivity and high strength containers. For the purpose of this invention, the density of the resin is determined according to ASTM standard test procedure D792.

[0021] The melt index (I2, as determined by ASTM D1238) of the resins used to prepare the container of this invention must be from 30 to 100 g/10 min. The preferred melt index range is from 50 to 90 g/10 min. The melt index of a polyethylene copolymer resin is also established by the molecular structure. Molecular weight is particularly important and is inversely related to melt index I2. That is, an increase in molecular weight will generally reduce the ability of the copolymer to flow (and thus cause an decrease in I2). High melt indices (lower molecular weights) are desirable to increase machine productivity but high molecular weight is desirable for strength.

[0022] The ethylene copolymer resins used to prepare the containers of this invention are further characterized by having a molecular weight distribution (as determined by dividing the weight average molecular weight “Mw” by the number average molecular weight “Mn”) of from 2.2 to 2.8.

[0023] Molecular weight determinations (Mw and Mn) are made by high temperature gel permeation chromatography (GPC) using techniques which are well known to those skilled in the art. It will be recognized by those skilled in the art that different GPC equipment and/or analytical techniques sometimes result in slightly different absolute values of weight average molecular weight (Mw) and number average molecular weight (Mn) for a given resin. Therefore, the resin used in this invention is defined by the ratio Mw/Mn.

[0024] We have determined that resins having a Mw/Mn of from 2.2 to 2.8 (and the density, I2, viscosity characteristic and hexane extractables level specified for this invention) provide containers having excellent strength and allow very good productivity.

[0025] The present containers are fabricated from ethylene copolymer resin which has apparent viscosity of less than 3.5 Pascal seconds when subjected to a shear rate of 100,000 s−1 at 280° C.

[0026] We have determined that this viscosity range provides strong containers and high machine productivity. Lower viscosity resins typically produce containers having inferior strength properties. Viscosity is measured according to ASTM D3835.

[0027] Finally, this invention uses a resin having a hexane extractables content (as determined by ASTM D5227) of less than 0.5 weight %.

[0028] The containers of this invention must be made from ethylene copolymer resin which satisfies all of the above criteria. Such resin may be prepared using the polymerization catalyst and polymerization process which is described in U.S. Pat. No. 6,372,864 (Brown et al.). Further details of the invention are provided in the following non-limiting examples.

EXAMPLES

[0029] Part 1: Test Procedures Used in the Examples

[0030] 1. “Instrumented Impact Testing” was completed using a commercially available instrument (sold under the tradename “INSTRON-DYNATUP”) according to ASTM D3763.

[0031] 2. Melt Index: 12 and 16 were determined according to ASTM D1238.

[0032] 3. Stress exponent is calculated by 1 log ⁡ ( I 6 / I 2 ) log ⁡ ( 3 ) .

[0033] 4. Number average molecular weight (Mn), weight average molecular weight (Mw), z-average molecular weight (Mz) and polydispersity (calculated by Mw/Mn) were determined by high temperature Gel Permeation Chromatography (“GPC”).

[0034] 5. Flexural Secant Modulus and Flexural Tangent Modulus were determined according to ASTM D790.

[0035] 6. Elongation, Yield and Tensile Secant Modulus measurements were determined according to ASTM D636.

[0036] 7. Hexane Extractables were determined according to ASTM D5227.

[0037] 8. Densities were determined using the displacement method according to ASTM D792.

[0038] 9. “Drop Testing” was completed according to ASTM D5276.

[0039] Part 2: Preparation of an Injection Molded Container

[0040] For the resins in Example 1, containers were prepared using an injection molding apparatus sold under the tradename Husky LX 225 P60/60 E70. The mold used for these samples was a 4-cavity mold making containers with a nominal outside diameter of 4.35 inches (11.0 cm), a thickness of 0.025 inches (0.6 mm) and a volume of 750 mL. Details of the Husky LX 225 P60/60 E70 thin wall injection molding (TWIM) machine are below: 1 Husky X 225 P60/50 E70 Clamp: 250 tons Plunger:  50 mm Screw:  70 mm Screw L/D Ratio: 25:1 Melt Channel Diameter:  8 mm

[0041] Conventional barrel temperatures for this apparatus typically range from 150 to 300° C. For the resins in Example 1, barrel temperatures ranged from 200 to 250° C., depending on the position in the barrel. Details on temperatures and other molding conditions are tabulated in Example 1.

[0042] Part 3: Preparation of an Injection Molded Lid

[0043] The machine sold under the tradename Husky LX 225 P60/60 E70 was also used for the resins in Example 2. The mold used for these samples was a 6-cavity mold making round lids for the containers produced in Example 1. The lids produced have a nominal outside diameter of 4.68 inches (11.9 cm) and a thickness of 0.04 inches (1.0 mm). Barrel temperatures were cooler than for the resins in Example 1, at 200 to 230° C. Details on temperatures and other molding conditions are tabulated in Example 2.

Example 1

[0044] Inventive resins E1 and E2 were characterized and compared to three commercially available resins used in this application (Table 1). E1 is a higher molecular weight, broader molecular weight distribution resin while E2 provides the lowest molecular weight and narrowest molecular weight distribution of the five resins studied. The data in Table 1 were collected using conventional ASTM testing techniques on resin pellets and compression molded plaques. 2 TABLE 1 Characterization of Experimental Container Resins E1 & E2 vs. Benchmarks* Units C1 E1 C2 C3 E2 Density g/cm3 0.9493 0.9516 0.9513 0.9536 0.9517 I2 g/10 min 56 69 73 86 95 I6 g/10 min 265 268 280 323 352 Stress Exponent 1.43 1.24 1.23 1.21 1.19 I21 g/10 min 836 838 772 805 834 Melt Flow Ratio 15 12 10.5 9.3 8.81 Viscosity @ 100000 sec−1 @ 250° C. Pa-sec 3.6 3.9 4.2 3.8 3.9 Viscosity @ 100000 sec−1 @ 280° C. Pa-sec 3.1 3.4 3.4 3.4 3.4 No. Ave. Mol. Wt. (Mn) ×10−3 10.3 13.1 9.8 10.4 13.9 Wt. Ave. Mol. Wt. (Mw) ×10−3 40.8 34.6 35.3 34.0 32.3 Z Ave. Mol. Wt. (Mz) ×10−3 152.5 75.8 77.2 70.4 59.7 Polydispersity Index 3.96 2.64 3.58 3.27 2.32 Hexane Extractables % 0.81 0.24 0.78 0.70 0.29 Melting Point ° C. 126.7 128.9 128.1 128.0 129.0 Crystallinity % 71.7 75.9 69.3 69.0 81.4 Vicat Softening Point ° C. 119 124 121 122 124 Shore D Hardness 66.4 67.2 66.3 66.1 67.2 Flex. Sec Modulus, 1% MPa 934 1128 1177 1208 1161 Flex. Sec Modulus, 2% MPa 809 994 1024 1058 1010 Flexural Strength MPa 27.9 35.2 33.1 35.6 35.5 Yield Elongation % 6 15 7 8 11 Yield Strength MPa 23.5 26.8 25.3 27.8 26.3 Ultimate Elongation % 7 24 7 8 12 Ultimate Strength MPa 23.7 25 25.3 27.8 26.3 Tensile Impact ft-lb/in2 9.39 38 23.5 21.7 22.6 Whiteness Index 79.21 91.3 87.58 90 91.38 Yellowness Index −3.31 −7.23 −6.22 −6.56 −7.04 *Physical test data from compression molded plaques. C1 is a polyethylene resin sold under the tradename Equistar H5057. C2 is a polyethylene resin sold under the tradename SCLAIR 2815. C3 is a polyethylene resin sold under the tradename SCLAIR 2717.

[0045] The data in Table 1 show that the experimental resins provide by far the lowest hexane extractable content, making them suitable for food applications. Their higher crystallinity, Vicat softening point, Shore D hardness and Flexural Modulus suggest their suitability for higher temperature filling and capping operations, (e.g. ricotta cheese). This data set also shows that the experimental resins should provide equivalent toughness and better color in comparison to incumbent products used in this market.

[0046] Container products were produced using the five resins in Table 1. They were produced on the Husky injection molding unit described above using the conditions listed in Table 2. 3 TABLE 2 Husky Injection Molding Machine Settings and Variables for Molding Container Resins Units C1 E1 C2 C3 E2 Resin Specs MI g/10 min 56 69 73 86 95 Density g/cm3 0.9493 0.9516 0.9513 0.9536 0.9517 S. Ex. 1.43 1.24 1.23 1.21 1.19 M/C Settings Fill pressure % 78 78 78 78 78 High Speed enable start mm 70 70 70 70 70 High Speed enable stop mm 30 32 30 34 36 Pullback mm 12 12 12 12 25 Gate heat % on 75 75 75 75 50 Barrel temperature Zone 1 ° C. 200 200 200 200 200 Barrel temperature Zone 2 ° C. 210 210 210 210 210 Barrel temperature Zone 3 ° C. 220 220 220 220 220 Barrel temperature Zone 4 ° C. 230 230 230 230 230 Barrel temperature Zone 5 ° C. 250 250 250 250 250 Variables Shot weight g 104.09 104.36 104.25 104.47 104.77 Cycle time sec 5.78 5.80 5.88 5.81 5.80 Injection time sec 0.36 0.39 0.41 0.39 0.40 Screw run time sec 2.11 2.03 2.03 2.06 2.07 Screw back pres psi 245 245 248 254 248 Ext. drive pres psi 1059 1115 1131 1085 1045 Max. inj. Pres psi 2236 2219 2230 2217 2205 Hold pressure Zone 1 psi 1088 1087 1087 1088 1088 Hold pressure Zone 2 psi 635 636 637 631 630 Hold pressure Zone 3 psi 301 303 304 302 302 Barrel temperature Zone 1 ° C. 200 200 200 197 200 Barrel temperature Zone 2 ° C. 211 211 211 208 211 Barrel temperature Zone 3 ° C. 221 221 221 221 221 Barrel temperature Zone 4 ° C. 230 230 230 230 230 Barrel temperature Zone 5 ° C. 251 251 251 251 251

[0047] In a conventional injection molding cycle, the molten resin is injected into a closed mold which is water cooled. It is desirable to maximize the productivity of these expensive machines, while also reducing energy requirements. In order to achieve this, the resin must have excellent rheological properties so that the resin flows sufficiently to completely fill the mold.

[0048] Table 2 provides data which show that the resin E2 from Example 1 requires lower pressure to mold a part. As a result, the barrel temperatures may be lowered in order to reduce energy consumption while maintaining cycle time. Conversely, temperatures could be maintained with a reduced cycle time, thus increasing the molding unit's unit productivity.

[0049] Conventional resins used in thin wall injection molding (TWIM) container applications are typically of medium to high density and also exhibit higher molecular weight than resins used in thin wall injection molding (TWIM) lid applications. The typical tradeoff in these applications is that if a stiffer product is desired, density is increased at the expense of product toughness. Similarly, if better product toughness is desired, the density of the resin is reduced somewhat and molecular weight of the resin is also increased, lowering the melt index and making the resin more difficult to process.

[0050] Extensive physical testing of the containers yielded the data in Table 3. It is clear that in general, the superior properties of the experimental resins predicted in Table 1 follow through to the injection molded parts. What is surprising is that the experimental resins, (while providing equivalent stiffness, as indicated by the retention of density for various positions on the part relative to the maximum density available, i.e. pellet density), also provide enhanced toughness, both at low and ambient temperature. This “decoupling” of the stiffness/toughness balance appears to apply at both lower and higher melt index. This is illustrated by the part drop test data, as defined by ASTM D5276. It shows that the experimental resins provide a pass at nearly twice the height of the incumbent resins. 4 TABLE 3 Injection Molded Containers Units C1 E1 C2 C3 E2 Pellet Density g/cm3 0.9493 0.9516 0.9513 0.9536 0.9517 Melt Index I2 g/10 min 56 69 73 86 95 Melt Index I6 g/10 min 265 268 280 323 352 Stress Exponent 1.43 1.24 1.23 1.21 1.19 Part Density - gate g/cm3 0.941 0.9429 0.9424 0.9428 0.943 mid floor g/cm3 0.9399 0.9419 0.9411 0.9412 0.942 step g/cm3 0.94 0.9421 0.9413 0.9414 0.9421 skirt g/cm3 0.9405 0.9427 0.9412 0.943 0.9428 Melt Index I2 g/10 min 55 71 70 81 93 Melt Index I6 g/10 min 266 281 269 296 328 Stress Exponent 1.44 1.25 1.23 1.18 1.15 Tensile Properties MD Elong. at Yield % 17 14 17 17 14 Yield Strength MPa 18 21.1 19.9 19.9 21.5 Ultimate Elong. % 650 1093 1138 391 1077 Ultimate Strength MPa 18.8 19.7 18.8 13.9 16.9 TD Elong. At Yield % 15 12 15 16 13 Yield Strength MPa 10.8 13.2 11.6 12 12.9 Ultimate Elong. % 185 423 337 197 325 Ultimate Strength MPa 10.8 13.2 11.6 12 12.9 Impact T sting Max. Load @ 23° C. on wall lb 121 118 122 119 117 Total Energy @ 23° C. on wall ft-lb 2.85 3.59 2.04 1.82 3.06 Max. Load @ −20° C. on wall lb 165 153 159 151 148 Total Energy @ −20° C. on wall ft-lb 2.84 2.44 2.52 2.05 3.25 Max. Load @ 23° C. on bottom lb 14 11 12 12 24 Total Energy @ 23° C. ft-lb 0.51 0.42 0.4 0.42 0.46 on bottom Max. Load @ −20° C. lb 19 10 15 13 30 on bottom Total Energy @ −20° C. ft-lb 0.11 0.31 0.11 0.16 0.23 on bottom Initial Tear Resistance MD Load At Max. N 66.4 68.3 72.7 61 54.5 Stress At Max. N/mm 103.1 107.2 112.9 95.5 89.5 % Strain At Max. % 16.7 4.5 6.6 4.3 2.5 TD Load At Max. N 89 94 95.2 82.6 64.5 Stress At Max. N/mm 139.1 148.1 153.6 126.1 105 % Strain At Max. % 66.4 68.7 74.1 38.9 5.5 Whiteness Index (part) 77.58 88.84 86.57 88.32 87.26 Yellowness Index (part) −4.76 −8.3 −8.82 −9.76 −7.89 Part Drop Test (Bruceton Staircase) Ave. Pass Drop Height ft 1.6 2.7 1.5 1.3 2.6 Max Pass Height ft 3 5 3 3 5 Min Pass Height ft 1 1 1 1 1 Part Shrinkage, 72 hours % 2.15 1.82 2.12 2.11 1.80

Example 2

[0051] Parallel to Example 1, Table 4 provides characterization results of experimental resins E3 and E4 in comparison to four competitive grades in the TWIM lid market. In similar fashion to the container resins, the experimental lid resins have significantly lower extractables content making them well suited for food applications. They also provide equivalent crystallinity at a lower melting point along with a higher Vicat softening point temperature and equivalent Shore D hardness. This combination of properties suggests lids produced from these resins would be suitable for hot fill applications, such as those described above for the experimental container resins. They also appear to have equivalent or slightly better toughness and equivalent color properties. 5 TABLE 4 Characterization of Experimental Lid Resins E3 & E4 vs. Benchmarks* Units C4 C5 C6 E3 C7 E4 Density (g/cm3) 0.9311 0.9319 0.9354 0.9324 0.9308 0.9321 I2 g/10 min 117 118 132 150 156 168 I6 g/10 min 454 458 525 535 600 670 Stress Exponent 1.24 1.24 1.28 1.16 1.23 1.26 I21 g/10 min 665 844 820 840 845 846 Melt Flow Ratio 5.7 7.2 6.1 5.57 5.4 5.06 Viscosity @ 100000 sec−1 @ 230° C. Pa-sec 3.6 3.5 2.9 3.7 3.3 2.8 Viscosity @ 100000 sec−1 @ 250° C. Pa-sec 3.2 3 2.7 3.3 2.8 2.6 No. Ave. Mol. Wt. (Mn) ×10−3 10.0 9.1 8.3 10.6 10.5 9.1 Wt. Ave. Mol. Wt. (Mw) ×10−3 30.0 29.7 30.7 28.6 28.4 29.2 Z Ave. Mol. Wt. (Mz) ×10−3 60.6 60.4 74.3 51.2 55.9 67.3 Polydispersity Index 3.00 3.27 3.72 2.70 2.70 3.20 Hexane Extractables wt % 3.50 3.27 4.49 0.87 2.26 1.30 Melting Point ° C. 122.2 123.6 125.8 119.5 124.0 119.0 Crystallinity % 44.0 52.4 56.6 63.7 55.9 56.8 Vicat Softening Point ° C. 90 87 96 104 96 101 Shore D Hardness 57.1 59.5 60.3 59.6 59.6 60.2 Flex. Sec Modulus, 1% MPa 475 627 631 569 498 534 Flex. Sec Modulus, 2% MPa 444 577 580 513 464 486 Flex. Strength MPa 17.1 21.3 21 20.5 17.7 19.9 Yield Elongation % 11 10 11 18 13 17 Yield Strength MPa 15 15.7 16.6 16.6 15 16.2 Ultimate Elongation % 40 36 76 54 47 46 Ultimate Strength MPa 12.9 12.7 11.1 9.3 12.9 12.6 Tensile Impact ft-lb/in2 34.9 37.8 40.1 49.8 42.8 43.6 Whiteness Index 80.08 87.25 90.29 84.17 78.29 85.15 Yellowness Index −9.05 −10.15 −10.72 −9.31 −8.22 −9.98 *Physical test data from compression molded plaques. C4 is a polyethylene resin sold under the tradename SCLAIR 2813. C5 is a polyethylene resin sold under the tradename Equistar 5947. C6 is a polyethylene resin sold under the tradename DNDA 1081. C7 is a polyethylene resin sold under the tradename Dowlex 2507.

[0052] Lid products were produced using the six resins in Table 4. They were produced on the Husky injection molding unit mentioned above under the conditions listed in Table 5. These data indicate that the experimental resins process very similarly to the incumbent resins. In addition, the resin E4 requires lower pressure to mold a part. As a result, the barrel temperatures may be lowered in order to reduce energy consumption while maintaining cycle time, or cycle time reduced at the same temperature. 6 TABLE 5 Husky Injection Molding Machine Settings and Variables for Molding Lid Resins Units C4 C5 C6 E3 C7 E4 Resin Specs MI g/10 min 117 118 132 150 156 168 Density g/cm3 0.9311 0.9319 0.9354 0.9324 0.9308 0.9321 S. Ex. 1.24 1.24 1.28 1.16 1.23 1.26 M/C Settings Fill pressure % 65 55 55 50 55 50 Pullback mm 0 10 10 10 10 10 Hold pressure Zone 1 % 20 20 20 20 20 20 Hold pressure Zone 2 % 15 15 15 15 15 15 Hold pressure Zone 3 % 10 10 10 10 10 10 Barrel temperature Zone 1 ° C. 200 200 200 200 200 200 Barrel temperature Zone 2 ° C. 210 210 210 210 210 210 Barrel temperature Zone 3 ° C. 220 220 220 220 220 220 Barrel temperature Zone 4 ° C. 230 230 230 230 230 230 Barrel temperature Zone 5 ° C. 230 230 230 230 230 230 Variables Shot weight g 55.85 55.73 55.73 55.74 55.73 55.80 Cycle time sec 4.82 4.84 4.83 4.84 4.83 4.81 Injection time sec 0.37 0.37 0.36 0.38 0.37 0.36 Screw run time sec 1.40 1.32 1.40 1.40 1.44 1.56 Screw back pres psi 257 255 258 255 257 255 Ext. drive pres psi 867 888 827 882 818 767 Max. inj. Pres psi 851 845 778 832 770 725 Hold pressure z. 1 psi 545 426 426 376 422 375 Hold pressure z. 2 psi 271 271 271 270 270 271 Hold pressure z. 3 psi 220 221 223 220 220 221 Barrel temperature Zone 1 ° C. 200 197 199 197 200 200 Barrel temperature Zone 2 ° C. 209 207 209 208 211 211 Barrel temperature Zone 3 ° C. 220 219 219 220 221 221 Barrel temperature Zone 4 ° C. 230 227 228 229 230 230 Barrel temperature Zone 5 ° C. 230 229 229 231 230 230

[0053] Extensive physical testing of the lids yielded the data in Table 6. These data show that the experimental resins E3 and E4 retain their stiffness properties and provide excellent toughness. Additionally, these experimental resins provide vastly superior clarity. This clarity is apparent for the two experimental resins based on testing using ASTM D1003 (Table 6). Thus, text placed a short distance behind lids made from any of the incumbent resins is not even discernible, let alone legible, yet can be clearly read when placed a similar distance behind a lid made from the either of the experimental resins. At smaller distances, such as might occur in packaging a product like yogurt or coffee with a printed foil seal beneath the lid, this effect is less dramatic. However, the improved clarity would allow a customer to more easily read the label and thus make the product more attractive. 7 TABLE 6 Injection Molded Lids Units C4 C5 C5 E3 C7 E4 Pellet Density g/cm3 0.9311 0.9319 0.9354 0.9324 0.9308 0.9321 Melt Index I2 g/10 min 117 118 132 150 156 168 Melt Index I6 g/10 min 454 458 525 535 600 670 Stress Exponent 1.24 1.24 1.28 1.16 1.23 1.26 Part Density - gate g/cm3 0.9267 0.9269 0.9264 0.9276 0.9259 0.9274 mid floor g/cm3 0.9256 0.9264 0.9256 0.9267 0.9253 0.9265 step g/cm3 0.9254 0.926 0.9254 0.9265 0.9249 0.9265 skirt g/cm3 0.9257 0.9268 0.9261 0.9276 0.9258 0.9271 Melt Index I2 g/10 min 118 114 129 148 152 171 Melt Index I6 g/10 min 458 444 515 534 571 676 Stress Exponent 1.24 1.24 1.26 1.17 1.21 1.25 Tensile Properties MD Elong. at Yield % 23 22 21 19 24 20 Yield Strength MPa 10.4 11.2 12.4 12 10.6 11.6 Ultimate Elong. % 238 209 318 337 287 312 Ultimate Strength MPa 9 9.4 9.6 9.8 8.9 9.6 TD Elong. at Yield % 21 20 20 20 22 20 Yield Strength MPa 10.8 11.5 12 11.9 10.2 11.9 Ultimate Elong. % 94 149 469 103 141 234 Ultimate Strength MPa 9.8 8.6 8.8 8.6 8.4 9 Impact Testing Max. Load @ 23° C. on Gate lb 99 97 105 107 101 105 Total Energy @ 23° C. on Gate ft-lb 3.06 3.07 3.27 3.19 3.14 3.2 Max. Load @ −20° C. on Gate lb 149 144 151 103 114 152 Total Energy @ −20° C. on Gate ft-lb 4.9 5.13 5.23 2.86 4.17 5.4 Max. Load @ 23° C. off Gate lb 93 92 87 94 100 93 Total Energy @ 23° C. off Gate ft-lb 2.62 2.74 2.7 2.92 3.04 2.82 Max. Load @ −20° C. off Gate lb 141 153 145 149 160 130 Total Energy @ −20° C. off Gate ft-lb 4.61 5.64 4.95 5.41 5.65 5.14 Initial Tear Resistance MD Load At Max. N 55.3 57.7 63 65.6 57.4 61.2 Stress At Max. N/mm 77.8 81.1 89.3 92.2 80.6 86.1 % Strain At Max. % 17.3 23.2 41.3 15.9 42.1 16.8 TD Load At Max. N 53.3 54.8 61.1 61.8 55.8 59.6 Stress At Max. N/mm 79.5 81.1 89.7 92.1 82.6 90.2 % Strain At Max. % 44.2 32.8 37 35.9 62.2 26.4 Whiteness Index WI, (part) 72.49 75.26 81.2 77.36 74.52 75.64 Yellowness Index, YI (part) −15.94 −12.76 −15.56 −8.62 −13.69 −8.57 Gloss % 54 54 54 55 54 55 Haze % 87.3 93.9 94.5 78 90.9 81.1 Clarity % 13 20 7 98 15 98 Part Shrinkage, 96 hours % 1.82 1.82 1.87 1.78 1.81 1.79

Claims

1. A container having a nominal volume of from 100 mL to 12 L prepared by injection molding of ethylene copolymer resin, said container having a Vicat softening point of greater than 121° C. and an average test drop height point of greater than 2.5 feet as determined by ASTM D5276 wherein said ethylene copolymer resin is characterized by:

i) a density from 0.950 g/cc to 0.955 g/cc;

ii) a viscosity at 100,000 sec−1 shear rate and 280° C. of less than 3.5 Pascal seconds;

iii) a molecular weight distribution, Mw/Mn of from 2.2 to 2.8; and

iv) a hexane extractables content of less than 0.5 weight %.

2. The container of claim 1 which is further characterized by having a total impact energy required for wall failure of greater than 3.0 foot-pounds at 23° C.

3. The container of claim 1 which is further characterized by having a total impact energy required for base failure of greater than 0.20 foot-pounds at −20° C. as determined by ASTM D3763.