High ductility, high modulus and phthalate free impact resistant propylene copolymer

A process for producing a phthalate free impact resistant polypropylene copolymer comprising homopolymer portion and C2/C3 rubber portion interspersed therein, comprising:

• a) in a first polymerization step, polymerizing propylene in bulk or gas phase to produce a propylene homopolymer having at least 85% by weight of insoluble in xylene at 25° C.;
• and
• b) in a second polymerization step, polymerizing ethylene and propylene, in the presence of the propylene homopolymer from the first polymerization step, to produce the phthalate free impact resistant polypropylene copolymer;
• wherein the polypropylene copolymer has a flexural modulus value in a range of about 120 to 200 kpsi;
• wherein the polypropylene copolymer has 100% instrumented impact ductility at −30° C. and 6.7 m/s;
• wherein the polypropylene copolymer has a C2/C3 rubber content greater than 20% by weight;
• and
• wherein the polypropylene copolymer has a total ethylene content in a range of about 10 to 20 molar percent;
• wherein the second polymerization step occurs in the presence of a phthalate free Ziegler/Natta (Z/N) catalyst, wherein the Z/N catalyst comprises a urea component represented by Formula I:
• wherein R1, R2, R3, and R4, which may be identical or different, are independently hydrogen, an aliphatic hydrocarbon group having 1 to 20 carbon atoms, an alicyclic hydrocarbon group having 3-20 carbon atoms, an aromatic hydrocarbon group having 6-20 carbon atoms, or a hetero atom containing a hydrocarbon group of 1 to 20 carbon atoms, wherein two or more of R1, R2, R3, and R4 may be linked to form one or more saturated or unsaturated monocyclic or polycyclic rings.