Random Propylene Copolymer Compositions, Articles and Process

• US 20100197874A1
• Filed: 12/31/2009
• Published: 08/05/2010
• 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: Baugh, Daniel W. III, Martin, Peter S., Chen, Linfeng, Sheard, William G.
• Granted Patent: US 8,106,138 B2
• Time in Patent Office: Days
• US Class Current: 526/213
• 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

The present disclosure is directed to random propylene/α-olefin compositions, articles, and processes for producing the same. The present compositions contain a random copolymer of propylene and α-olefin. Polymerization with an improved catalyst composition increases the molecular weight distribution of the copolymer and increases the randomness of comonomer distribution to yield random propylene/α-olefin copolymers with improved stiffness and/or improved optical properties.

Claims

1. A polymerization process comprising:

contacting, under polymerization conditions, propylene and ethylene with a catalyst composition comprising a substituted phenylene aromatic diester; and

forming a random propylene/ethylene copolymer with a Koening B-value from about 0.83 to about 1.0.

2. The polymerization process of claim 1 comprising maintaining a H₂/C₃ molar ratio from 0.002 to 0.02 and forming a propylene/ethylene copolymer having a melt flow rate from 0.1 g/10 min to 5 g/10 min as measured in accordance with ASTM D 1238, 2.16 kg, 230°

C.

3. The polymerization process of claim 1 comprising maintaining a H₂/C₃ molar ratio from 0.010 to 0.25 and forming a propylene/ethylene copolymer having a melt flow rate from greater than 5 g/10 min to about 800 g/10 min as measured in accordance with ASTM D 1238, 2.16, 230°

C.

4. A composition comprising:

a random propylene/ethylene copolymer comprising a substituted phenylene aromatic diester.

5. The composition of claim 4 having a Koening B-value from about 0.83 to about 1.0.

6. The composition of claim 4 comprising 3-methyl-5-tert butyl-1,2 phenylene dibenzoate.

7. The composition of claim 4 wherein the random propylene/ethylene copolymer comprises an EEE triad less than 0.37.

8. The composition of claim 4 wherein the random propylene/ethylene copolymer comprises from about 1 wt % to about 10 wt % units derived from ethylene.

9. The composition of claim 4 wherein the random propylene/ethylene copolymer has a melt flow rate from about 0.1 g/10 min to about 5 g/10 min as measured in accordance with ASTM D 1238, 2.16 kg, 230°

C.

10. The composition of claim 9 wherein the random propylene/ethylene copolymer has a polydispersity index greater than 5.0.

11. The composition of claim 4 wherein the random propylene/ethylene copolymer has a melt flow rate greater than 5 g/10 min to about 800 g/10 min as measured in accordance with ASTM D 1238, 2.16 kg, 230°

C.

12. The composition of claim 11 wherein the random propylene/ethylene copolymer having a polydispersity index less than 5.0.

13. The composition of claim 4 wherein the composition is a plaque having a haze value less than about 15% as measured in accordance with ASTM D 1003.

14. The composition of claim 4 wherein the composition is phthalate-free.

15. An article comprising:

a composition comprising a random propylene/ethylene copolymer comprising a substituted phenylene aromatic diester.

16. The article of claim 15 wherein the article is a molded article selected from the group consisting of an extruded article, an injection molded article, a blow molded article, a rotation molded article, and a thermoformed article.

17. The molded article of claim 16 having a haze value less than 15% as measured in accordance with ASTM D 1003.

18. The molded article of claim 16 having a clarity greater than 98% as measured in accordance with ASTM D 1746.

19. The molded article of claim 16 having a gloss value greater than 90 as measured in accordance with ASTM D 523 (45°

).

20. The article of claim 15 wherein the article is a pipe comprising a random propylene/ethylene copolymer having a melt flow rate from 0.1 g/10 min to 5 g/10 min as measured in accordance with ASTM D 1238, 2.16 kg, 230°

C.