Multiple catalyst system for olefin polymerization and polymers produced therefrom
First Claim
1. A polymer comprising at least 50 mol % of one or more C3 to C40 olefins where the polymer has:
- a) a Dot T-Peel of 1 Newton or more on Kraft paper;
b) an Mw of 10,000 to 100,000;
c) a branching index (g′
) of from 0.4 to 0.98 measured at the Mz of the polymer when the polymer has an Mw of 10,000 to 60,000, or a branching index (g′
) of from 0.4 to 0.95 measured at the Mz of the polymer when the polymer has an Mw of 10,000 to 100,000;
d) a heat of fusion of 1 to 70 J/g; and
e) a heptane insoluble fraction of 70 weight % or less, based upon the weight of the polymer, where the heptane insoluble fraction has branching index g′
of 0.9 or less as measured at the Mz of the polymer.
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Abstract
This invention relates to a polymer comprising one or more C3 to C40 olefins, optionally one or more diolefins, and less than 15 mole % of ethylene, where the polymer has: a) a Dot T-Peel of 1 Newton or more; and b) a branching index (g′) of 0.95 or less measured at the Mz of the polymer; c) an Mw of 100,000 or less. This invention also relates a polymer comprising one or more C3 to C40 olefins where the polymer has: a) a Dot T-Peel of 1 Newton or more on Kraft paper; b) a branching index (g′) of 0.95 or less measured at the Mz of the polymer; c) a Mw of 10,000 to 100,000; and d) a heat of fusion of 1 to 70 J/g. This invention also relates a polymer comprising one or more C3 to C40 olefins where the polymer has: a) a Dot T-Peel of 1 Newton or more on Kraft paper; b) a branching index (g′) of 0.98 or less measured at the Mz of the polymer; c) a Mw of 10,000 to 60,000; d) a heat of fusion of 1 to 50 J/g. This invention also relates to a homopolypropylene or a copolymer of propylene and up to 5 mole % ethylene having: a) an isotactic run length of 1 to 30 (isotactic run length “IRL” is defined to be the percent of mmmm pentad divided by 0.5× percent of mmmr pentad) as determined by Carbon 13 NMR, preferably 3 to 25, more preferably 4 to 20, b) a percent of r dyad of greater than 20%, preferably from 20 to 70% as determined by Carbon 13 NMR, and c) a heat of fusion of 70 J/g or less, preferably 60 J/g or less, more preferably between 1 and 55 J/g, more preferably between 4 and 50 J/g. This invention further relates to a process to produce an olefin polymer comprising: 1) selecting a first catalyst component capable of producing a polymer having an Mw of 100,000 or less and a crystallinity of 5% or less at selected polymerization conditions; 2) selecting a second catalyst component capable of producing polymer having an Mw of 100,000 or less and a crystallinity of 20% or more at the selected polymerization conditions; 3) contacting the catalyst components in the presence of one or more activators with one or more C3 to C40 olefins, at the selected polymerization conditions in a reaction zone; 4) obtaining the polymer. This invention further relates to a continuous process to produce a branched olefin polymer comprising: 1) selecting a first catalyst component capable of producing a polymer having an Mw of 100,000 or less and a crystallinity of 5% or less under selected polymerization conditions; 2) selecting a second catalyst component capable of producing polymer having an Mw of 100,000 or less and a crystallinity of 20% or more at the selected polymerization conditions; 3) contacting the catalyst components in the presence of one or more activators with one or more C3 to C40 olefins, and, optionally one or more diolefins; 4) at a temperature of greater than 100° C.; 5) at a residence time of 120 minutes or less; 6) wherein the ratio of the first catalyst to the second catalyst is from 1:1 to 50:1; 7) wherein the activity of the catalyst components is at least 100 kilograms of polymer per gram of the catalyst components; and wherein at least 20% of the olefins are converted to polymer.
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Citations
61 Claims
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1. A polymer comprising at least 50 mol % of one or more C3 to C40 olefins where the polymer has:
-
a) a Dot T-Peel of 1 Newton or more on Kraft paper;
b) an Mw of 10,000 to 100,000;
c) a branching index (g′
) of from 0.4 to 0.98 measured at the Mz of the polymer when the polymer has an Mw of 10,000 to 60,000, or a branching index (g′
) of from 0.4 to 0.95 measured at the Mz of the polymer when the polymer has an Mw of 10,000 to 100,000;
d) a heat of fusion of 1 to 70 J/g; and
e) a heptane insoluble fraction of 70 weight % or less, based upon the weight of the polymer, where the heptane insoluble fraction has branching index g′
of 0.9 or less as measured at the Mz of the polymer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 61)
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35. A continuous process to produce a branched olefin polymer comprising:
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1) selecting a first catalyst component capable of producing a polymer having an Mw of 100,000 or less and a crystallinity of 5% or less under selected polymerization conditions;
2) selecting a second catalyst component capable of producing polymer having an Mw of 100,000 or less and a crystallinity of 20% or more at the selected polymerization conditions;
3) contacting the catalyst components in the presence of one or more activators with one or more C3 to C40 olefins; and
,4) at a temperature of greater than 100°
C.;
5) at a residence time of 1.20 minutes or less;
6) wherein the ratio of the first catalyst to the second catalyst is from 1;
1 to 50;
1;
7) wherein the activity of the catalyst components is at least 50 kilograms of polymer per gram of the catalyst compounds; and
wherein at least 80% of the olefins are converted to polymer; and
8) obtaining a polymer comprising at least 50 mol % of the C3 to C40 olefins where the polymer has;
a) a Dot T-Peel of 1 Newton or more on Kraft paper;
b) an Mw of 10,000 to 100,000;
c) a branching index (g′
) of from 0.4 to 0.98 measured at the Mz of the polymer when the polymer has an Mw of 10,000 to 60,000, or a branching index (g′
) of from 0.4 to 0.95 measured at the Mz of the polymer when the polymer has an Mw of 10,000 to 100,000;
d) a heat of fusion of 1 to ′
70 J/g; and
e) a heptane insoluble fraction 70 weight % or less, based upon the weight of the polymer, and the heptane insoluble fraction has branching index g′
of 0.9 or less as measured at the Mz of the polymer. - View Dependent Claims (36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56)
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57. A composition comprising a homopolymer of propylene and or a copolymer of propylene and one or more of butene, pentene, hexene, octene, nonene, and decene, wherein the copolymer comprises less than 50 mole % ethylene, and wherein the homopolymer or copolymer has a Dot T-Peel of 3 or more Newtons;
- a viscosity of 8000 mPa·
sec or less at 190°
C.;
a branching index (g′
) of from 0.4 to 0.85 measured at the Mz of the polymer;
an Mw of 100,000 or less;
a heat of fusion of 1 to 70 J/g; and
a heptane insoluble fraction 70 weight % or less, based upon the weight of the polymer, and the heptane insoluble fraction has branching index g′
of 0.9 or less as measured at the Mz of the polymer.
- a viscosity of 8000 mPa·
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58. A composition comprising a. polymer of propylene, having from 0 to 5 mol % ethylene and from 0 to 40 mol % of a C5 to C12 olefin, and 0 to 10 mol % of a diene where the polymer has:
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a) a Dot T-Peel of 1 Newton or more; and
b) an Mw of 100,000 or less; and
c) a Mz/Mn of 2-200; and
d) an Mw of 100,000 or less and a branching index of from 0.4 to 0.5, or an Mw of 75,000 or less and a branching index of from 0.4 to 0.6, or an Mw of 50,000 or less and a branching index of from 0.4 to 0.7, or an Mw of 30,000 or less and a branching index of from 0.4 to 0.98; and
d) a peak melting point between 60 and 190°
C., ande) a viscosity of 8000 mPa·
sec or less at 190°
C.; and
f) a heat of fusion from 1 to 70 J/g; and
g) a Shore A Hardness (as measured by ASTM
2240) of 70 or less; and
h) A Shear Adhesion Fail Temperature 40 to 150°
C.; and
i) a set time of 5 seconds or less; and
j) an Mw/Mn of 3 to 75; and
k) an Mz of 20,000 to 500,000; and
l) a melt index of 900 dg/min or less; and
m) a heptane insoluble fraction of 70 weight % or less, based upon the weight of the polymer, where the heptane insoluble fraction has branching index g′
of 0.9 or less as measured at the Mz of the polymer.
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59. A polymer comprising one or more C3 to C40 olefins, optionally one or more diolefins, and less than 1 mole % of ethylene where the polymer has:
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a) a Dot T-Peel of I Newton or more; and
b) a branching index (g′
) of from 0.4 to 0.95 measured at the Mz of the polymer; and
c) an Mw of 100,000 or less; and
d) at least 2 mol % (CH2)2 units; and
e) a heat of fusion of 1 to 70 J/g; and
f) a heptane insoluble fraction of 70 weight % or less, based upon the weight of the polymer, where the heptane insoluble fraction has branching index g′
of 0.9 or less as measured at the Mz of the polymer.
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60. A polymer comprising one or more C3 to C40 olefins, optionally one or more diolefins, and less than 50 mole % of ethylene where the polymer has:
-
a) a Dot T-Peel of 5 Newton or more ; and
b) a branching index (g′
) of from 0.4 to 0.95 measured at the Mz of the polymer; and
c) an Mw of 100,000 or less; and
d) a heat of fusion of 1 to 70 J/g; and
e) a heptane insoluble fraction 70 weight % or less, based upon the weight of the polymer, and the heptane insoluble fraction has branching index g′
of 0.9 or less as measured at the Mz of the polymer.
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Specification