Propylene-Based Polymer, Articles, and Process for Producing Same

• US 20100168353A1
• Filed: 12/31/2009
• Published: 07/01/2010
• Est. Priority Date: 12/31/2008
• Status: Active Grant

• Current Assignee: W R Grace & Company - CONN (WR Grace & Company)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Chen, Linfeng, Sheard, William G.
• Granted Patent: US 8,263,692 B2
• Time in Patent Office: Days
• US Class Current: 526/191
• CPC Class Codes: C07C 37/02 by substitution of halogen
• CPC Class Codes: C07C 37/14 by addition reactions, i.e. reactions involving at least one carbon-to-carbon unsaturated bond
• CPC Class Codes: C07C 37/16 by condensation involving hydroxy groups of phenols or alcohols or the ether or mineral ester group derived therefrom
• CPC Class Codes: C07C 37/50 by reactions decreasing the number of carbon atoms C07C37/04, C07C37/045, C07C37/055, C07C37/08 take precedence
• CPC Class Codes: C07C 37/56 by replacing a carboxyl or aldehyde group by a hydroxy group
• CPC Class Codes: 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
• CPC Class Codes: C07C 39/08 Dihydroxy benzenes; Alkylated derivatives thereof
• CPC Class Codes: C07C 67/14 from carboxylic acid halides
• CPC Class Codes: C07C 69/78 Benzoic acid esters
• CPC Class Codes: C08F 10/06 Propene
• CPC Class Codes: C08F 110/06 Propene
• CPC Class Codes: C08F 210/06 Propene
• CPC Class Codes: C08F 210/16 Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
• CPC Class Codes: C08F 2410/06 Catalyst characterized by its size
• CPC Class Codes: C08F 2500/12 Melt flow index or melt flow ratio
• CPC Class Codes: C08F 2500/18 Bulk density
• CPC Class Codes: C08F 4/6465 containing silicium
• CPC Class Codes: C08F 4/6494 containing oxygen
• CPC Class Codes: C08F 4/651 Pretreating with non-metals or metal-free compounds
• CPC Class Codes: C08F 4/6545 and metals of C08F4/64 or compounds thereof

Abstract

Disclosed are propylene-based polymer compositions and processes for producing same. Polymerization with an improved catalyst composition provides a propylene-based polymer with improved stiffness.

Claims

1. A polymerization process comprising:

contacting, under polymerization conditions, propylene and optionally at least one other olefin with a catalyst composition comprising a substituted phenylene aromatic diester; and

forming a propylene-based polymer with a flexural modulus greater than 260 kpsi as determined by ASTM D 790.

2. The process of claim 1 wherein the contacting further comprises adding an activity limiting agent.

3. The process of claim 1 wherein the catalyst composition comprises aluminum and an external electron donor (EED), the process comprising maintaining an aluminum to EED molar ratio of less than 5.0 during the contacting.

4. The process of claim 1 further comprising nucleating the formed propylene-based polymer and producing a nucleated propylene-based polymer with a flexural modulus of greater than 322 kpsi as determined by ASTM D 790.

5. The process of claim 1 further comprising contacting the formed propylene-based polymer with at least one olefin in a second reactor under polymerization conditions;

and forming a propylene impact copolymer.

6. A composition comprising:

a propylene homopolymer; and

a substituted phenylene aromatic diester.

7. The composition of claim 6 wherein the substituted phenylene aromatic diester is selected from the group consisting of substituted 1,2 phenylene dibenzoate, 3-methyl-5-tert butyl-1,2 phenylene dibenzoate, and 3,5-diisopropyl-1,2 phenylene dibenzoate.

8. The composition of claim 6 wherein the substituted phenylene aromatic diester is 3-methyl-5-tert butyl-1,2 phenylene dibenzoate.

9. The composition of claim 6 wherein the propylene homopolymer has a flexural modulus of greater than 260 kpsi as determined by ASTM D 790.

10. The composition of claim 6 wherein the propylene homopolymer is nucleated.

11. The composition of claim 10 wherein the nucleated propylene homopolymer has a flexural modulus of greater than 322 kpsi as determined by ASTM D 790.

12. The composition of claim 6 wherein the propylene homopolymer has a polydispersity index of 8.0 or less.

13. The composition of claim 6 wherein the propylene homopolymer has a xylene soluble content less than or equal to 1.5% by weight.

14. The composition of claim 6 wherein the propylene homopolymer has isotactic (mmmm) pentads higher than 97%, as determined by ¹³C-NMR analysis.

15. The composition of claim 6 wherein the propylene homopolymer has a melt flow rate from 50 g/10 min to 100 g/10 min as measured in accordance with ASTM D 1238 (230°

C., 2.16 kg).

16. The composition of claim 6 wherein the propylene homopolymer has a melt flow rate of 50 g/10 min and an oligomer content less than 1800 ppmw.

17. A composition comprising:

a non-nucleated propylene homopolymer having a polydispersity index less than 6.0, a flexural modulus greater than 283 kpsi and a melt flow rate greater than or equal to 50 g/10 min as measured in accordance with ASTM D 1238 (230°

C., 2.16 kg); and

an oligomer content of less than 1800 ppmw.

18. The composition of claim 17 wherein the propylene-based polymer has a xylene soluble content less than or equal to 1.5% by weight.

19. The composition of claim 17 comprising a substituted phenylene aromatic diester.

20. The composition of claim 17 comprising 3-methyl-5-tert butyl-1,2 phenylene dibenzoate.