# US 2010/0168342 A1 · Propylene Impact Copolymer and Method

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- Number: US 2010/0168342 A1
- Document ID: US20100168342A1
- Status: Published application
- Kind: A1
- Application number: 12/650,625
- Filed: 2009-12-31
- Published: 2010-07-01
- Earliest claimed: 2008-12-31
- Assignees: Dow Global Technologies LLC
- Inventors: William G. Sheard; Linfeng Chen
- Web page: https://patentgrep.com/patent/US20100168342A1

## CPC

- C08F 10/06: Propene
- C07C 37/02: by substitution of halogen
- C07C 37/14: by addition reactions, i.e. reactions involving at least one carbon-to-carbon unsaturated bond
- C07C 37/16: by condensation involving hydroxy groups of phenols or alcohols or the ether or mineral ester group derived therefrom
- C07C 37/50: by reactions decreasing the number of carbon atoms (C07C37/04, C07C37/045, C07C37/055, C07C37/08 take precedence)
- C07C 37/56: by replacing a carboxyl or aldehyde group by a hydroxy group
- C07C 37/60: by oxidation reactions introducing directly hydroxy groups on a =CH-group belonging to a six-membered aromatic ring with the aid of other oxidants than molecular oxygen or their mixtures with molecular oxygen
- C07C 67/14: from carboxylic acid halides
- C08F 110/06: Propene
- C08F 210/06: Propene
- C08F 2410/06: Catalyst characterized by its size
- C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS

## Abstract

Disclosed are propylene impact copolymer compositions, articles thereof, and processes for producing same. Polymerization with an improved catalyst composition provides a propylene impact copolymer with high melt flow and low volatiles content.

## Claims

### Claim 1

A polymerization process comprising:
contacting, under polymerization conditions, propylene with a catalyst composition comprising a substituted phenylene aromatic diester in a first polymerization reactor;
forming an active propylene-based polymer;
contacting, under polymerization conditions, the active propylene-based polymer with at least one olefin in a second polymerization reactor; and
forming a propylene impact copolymer comprising a substituted phenylene aromatic diester.

### Claim 2 (depends on 1)

The process of claim 1 comprising forming a propylene impact copolymer having a volatiles content less than about 30 μg/g in accordance with VW standard PV3341.

### Claim 3 (depends on 1)

The process of claim 1 wherein the catalyst composition comprises aluminum, the process comprising adding an external electron donor to at least one of the polymerization reactors and maintaining an Al:EED ratio of less than 5.0.

### Claim 4 (depends on 3)

The process of claim 3 comprising adding a single external electron donor.

### Claim 5 (depends on 1)

The process of claim 1 comprising forming an active propylene-based polymer having a melt flow rate greater than 100 g/10 min as measured in accordance with ASTM D 1238, 2.16 kg, 230° C.

### Claim 6 (depends on 1)

The process of claim 1 comprising forming a propylene impact copolymer having a melt flow rate greater than 40 g/10 min as measured in accordance with ASTM D 1238, 2.16 kg, 230° C.

### Claim 7 (depends on 1)

The process of claim 1 comprising maintaining a H2/C3 mole ratio of greater than 0.1 in the second polymerization reactor.

### Claim 8 (depends on 1)

The process of claim 1 comprising contacting, in the second polymerization reactor, the active propylene-based polymer with propylene and ethylene and forming a propylene impact copolymer having an Fc value from about 5 wt % to about 50 wt % and an Ec value from about 20 wt % about 90 wt %.

### Claim 9

A propylene impact copolymer comprising:
a propylene-based polymer;
a propylene/ethylene copolymer dispersed within the propylene-based polymer; and
a substituted phenylene aromatic diester.

### Claim 10 (depends on 9)

The propylene impact copolymer of claim 9 wherein the substituted phenylene diester is present in a member selected from the group consisting of the propylene-based polymer, the propylene/ethylene copolymer, and combinations thereof.

### Claim 11 (depends on 9)

The propylene impact copolymer of claim 9 comprising 3-methyl-5-tert-butyl-1,2 phenylene dibenzoate.

### Claim 12 (depends on 9)

The propylene impact copolymer of claim 9 having a volatiles content less than about 30 μg as measured in accordance with VW standard PV3341.

### Claim 13 (depends on 9)

The propylene impact copolymer of claim 9 wherein the propylene-based polymer has a melt flow rate (MFR) greater than about 100 g/10 min as measured in accordance with ASTM D 1238-01 (230° C., 2.16 kg).

### Claim 14 (depends on 9)

The propylene impact copolymer of claim 9 wherein the propylene impact copolymer has a melt flow rate (MFR) greater than about 40 g/10 min as measured in accordance with ASTM D 1238-01 (230° C., 2.16 kg).

### Claim 15 (depends on 9)

The propylene impact copolymer of claim 9 wherein the propylene-based polymer has a property selected from the group consisting of a xylene solubles content less than about 4%, a TMF greater than about 170° C., and combinations thereof.

### Claim 16 (depends on 9)

The propylene impact copolymer of claim 9 wherein the propylene impact copolymer has an Fc value from about 5 wt % to about 50 wt %, an Ec value from about 20 wt % to about 90 wt %.

### Claim 17

An article comprising:
a propylene impact copolymer comprising 3-methyl-5-tert-butyl-1,2 phenylene dibenzoate.

### Claim 18

(canceled)

### Claim 19 (depends on 17)

The article of claim 17 having a volatiles content less than about 30 μg/g as measured in accordance with VW standard PV3341.

### Claim 20 (depends on 17)

The article of claim 17 selected from the group consisting of an extruded article, an injection molded article, a rotational molded article, a blow molded article, and a thermoformed article.

### Claim 21 (depends on 17)

The article of claim 17 wherein the propylene impact copolymer has a melt flow rate greater than about 40 g/10 min as measured in accordance with ASTM D 1238-01 (230° C., 2.16 kg).