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US 10,119,016 B2Granted
Heterophasic copolymers and sequential polymerization
AssigneeExxonMobil Chemical Patents Inc.
InventorsLubin Luo, Gregory S. Day, Matthew W. Holtcamp
Life of this patent
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Abstract
This invention relates to heterophasic copolymers of propylene and an alpha olefin comonomer having a high fill phase content (≥15%), and heterophasic polymerization processes using a single site catalyst system with a support having high average particle size (PS≥30 μm), high surface area (SA≥400 m2/g), low pore volume (PV≤2 mL/g), and a mean pore diameter range of 1≤PD≤20 nm.
Claims25
A process for polymerization of propylene and a comonomer, comprising:
- (a) contacting propylene monomer under polymerization conditions with a first catalyst system, comprising a single site catalyst precursor compound, an activator, and a support having an average particle size of more than 30 microns, a surface area of 400 m2/g or more, a pore volume of from 0.5 to 2 mL/g, and a mean pore diameter of from 1 to 20 nm (10 to 200 angstroms) as determined by BET nitrogen adsorption, to form a matrix phase of propylene polymer comprising at least 50 mol% propylene and having a porosity of 15% or more as determined by mercury intrusion porosimetry;
- and
- (b) contacting an alpha olefin monomer selected from ethylene, C3 to C20 alpha olefins, or a combination thereof, including at least one alpha olefin other than propylene, with a second catalyst system under polymerization conditions to form a fill phase for the pores of the matrix, wherein the second catalyst system comprises a metallocene catalyst precursor compound, an activator, and a support, and wherein the second catalyst system comprises, compositionally, the same or different single site catalyst precursor compound as in the first catalyst system, the same or different activator as in the first catalyst system, the same or different support as in the first catalyst system, or any combination thereof,
- (c) obtaining a heterophasic propylene copolymer composition comprising:
- A) a matrix phase comprising at least 50 mol % propylene and having:
- 1) a 1% Secant flexural modulus of at least 1000 MPa, determined according to ASTM D 790 (A, 1.0 mm/min);
- 2)more than 5 and less than 200 regio defects (defined as the sum of 2,1-erythro and 2,1-threo insertions, and 3,1-isomerizations) per 10,000 propylene units, determined by 13C NMR;
- and
- 3) when comonomer is present, a composition distribution breadth index of 50% or more;
- and
- B) a fill phase at least partially filling pores in the matrix phase, wherein the fill phase comprises at least 30 wt % of the heterophasic propylene copolymer composition, based on the total weight of the matrix and fill phases.
8 more elements
A process for polymerization of propylene and a comonomer, comprising:
- (a) contacting propylene monomer under polymerization conditions with a first catalyst system, comprising a single site catalyst precursor compound, an activator, and a support having an average particle size of more than 30 microns, a surface area of 400 m2/g or more, a pore volume of from 0.5 to 2 mL/g, and a mean pore diameter of from 1 to 20 nm (10 to 200 angstroms) as determined by BET nitrogen adsorption, to form a matrix phase of propylene polymer comprising at least 50 mol % propylene and having a porosity of 15% or more as determined by mercury intrusion porosimetry;
- and
- (b) contacting an alpha olefin monomer selected from ethylene, C3 to C20 alpha olefins, or a combination thereof, including at least one alpha olefin other than propylene, with a second catalyst system under polymerization conditions to form a fill phase for the pores of the matrix, wherein the second catalyst system comprises a metallocene catalyst precursor compound, an activator, and a support, and wherein the second catalyst system comprises, compositionally, the same or different single site catalyst precursor compound as in the first catalyst system, the same or different activator as in the first catalyst system, the same or different support as in the first catalyst system, or any combination thereof.
Dependencies are inferred from the claim text.