High-density polyethylene (HDPE) packaging materials must maintain structural integrity across varied environmental conditions while meeting strict performance requirements. Current HDPE formulations achieve densities of 0.950-0.980 g/cm³, but environmental stress cracking can occur at stress points when exposed to temperature fluctuations and chemical agents, particularly in containers storing reactive materials.

The fundamental challenge lies in developing HDPE compositions that balance molecular weight distribution, crystallinity, and processability while maintaining resistance to environmental stress cracking.

This page brings together solutions from recent research—including multimodal molecular weight distributions, metallocene-catalyzed copolymer blends, and optimized ethylene-α-olefin compositions. These and other approaches demonstrate how manufacturers can achieve enhanced stress crack resistance while preserving essential mechanical properties for commercial packaging applications.

1. High-Density Polyethylene Composition with Ethylene Alpha Olefin Copolymer and Homopolymer in Specified Weight Ratio

LOTTE CHEMICAL CORP, 2020

High-density polyethylene composition and molded articles with improved properties for applications like beverage container closures. The composition contains two types of polyethylene: an ethylene alpha olefin copolymer with specific melt flow and density ranges, and an ethylene homopolymer. The copolymer provides impact strength and the homopolymer provides rigidity. The weight ratio of the copolymer to homopolymer is 35-65:65-35. The composition is melt-kneaded to prepare the molded articles like bottle caps. The copolymer's low-temperature impact strength and environmental stress cracking resistance are improved compared to homopolymer-only compositions.

2. High-Density Polyethylene Resin Blend with Multimodal Molecular Weight Distribution and Specified Melt Flow Rates

BOREALIS AG, 2016

Blend of high-density polyethylene (HDPE) resins with improved environmental stress crack resistance (ESCR) for injection, blow, and compression molding applications. The blend comprises a lower molecular weight multimodal HDPE component with density ≥ 940 kg/m3 and a higher molecular weight HDPE component. The lower molecular weight HDPE component has density ≥ 950 kg/m3 and an MFR of ≥ 50 g/10 min. The higher molecular weight HDPE component has density ≥ 950 kg/m3 and an MFR of ≤ 1.0 g/10 min. The blend provides ESCR ≥ 30 hours at 50°C and 6 MPa, which is higher than blends with only lower molecular weight HDPE.

AU2016200958B2-patent-drawing

3. Packaging Material Comprising Metallocene-Based Linear Low Density Copolymer and Polyolefin Blend

ASYA PLASTIK VE AMBALAJ SAN.TIC.LTD.STI, 2013

Packaging material with improved properties like durability, flexibility, brightness, and transparency compared to conventional packaging materials. The packaging material contains a unique composition of polymers like metallocene-based linear low density copolymer, low melting flow rate low density polyethylene, high density polyethylene, and high density polypropylene. This combination provides benefits like faster sealing, better load-bearing capacity, reduced deformation, enhanced strength, brighter appearance, and lower haze compared to conventional packaging materials.

4. Polyethylene Resin Composition with Specific Blend Ratios and Melt Characteristics for Heavy-Duty Packaging Bags

MITSUI CHEMICALS INC, 1999

Polyethylene resin composition for heavy-duty packaging bags that provides improved low-temperature properties, such as drop bag strength, for bags used in cold areas. The composition has a specific melt flow rate, density, and tension range. It uses a blend of linear low-density polyethylene (LLDPE), linear medium/high-density polyethylene (LDPE/HDPE), and high-pressure low-density polyethylene (HLLDPE). The blend ratios are 40-70% LLDPE, 1-55% LDPE/HDPE, and 5-29% HLLDPE.

CA2172941C-patent-drawing

5. Single-Layer Polyethylene Film with HDPE and L-LDPE Blend for Light-Shielding and Puncture Resistance

FUJI PHOTO FILM CO LTD, 1988

A packaging material for photosensitive materials like photographic film that is strong enough to prevent breakage and puncture during handling without being laminated. The material is a single film made from a specific blend of polyethylene resins. It contains 5-30 wt% of high density polyethylene (HDPE) with high melt index (>0.5 g/10 min) and density (>0.950 g/cm³), 50 wt% of linear low density polyethylene (L-LDPE), and 0.1-20 wt% of a light-shielding material. The HDPE provides strength and resistance to sharp edges, while the L-LDPE balances properties. The light-shielding material blocks light.

Get Full Report

Access our comprehensive collection of patents related to this technology