Heterophasic copolymers and sequential polymerization

Patent metadata

Field	Value
Publication number	US-9738779-B2
Application number	US-201615142377-A
Country	US
Kind code	B2
Filing date	Apr 29, 2016
Priority date	Jun 5, 2015
Publication date	Aug 22, 2017
Grant date	Aug 22, 2017

Abstract

This invention relates to heterophasic copolymers of propylene and an alpha olefin comonomer having a high fill phase content (≧15%), and heterophasic polymerization processes using a single site catalyst system with a support having high average particle size (PS≧30 μm), high surface area (SA≧400 m 2 /g), low pore volume (PV≦2 mL/g), and a mean pore diameter range of 1≦PD≦20 nm.

First claim

What is claimed is:

1. A heterophasic propylene copolymer composition comprising:
A) a matrix phase comprising at least 50 mol % propylene and having:
1) a 1% Secant flexural modulus of at least 1000 MPa, determined according to ASTM D 790 (A, 1.0 mm/min);
2) more than 5 and less than 200 regio defects (defined as the sum of 2,1-erythro and 2,1-threo insertions, and 3,1-isomerizations) per 10,000 propylene units, determined by 13 C NMR; and
3) when comonomer is present, a composition distribution breadth index of 50% or more; and

B) a fill phase at least partially filling pores in the matrix phase, wherein the fill phase comprises at least 30 wt % of the heterophasic propylene copolymer composition, based on the total weight of the matrix and fill phases.

2. The heterophasic propylene copolymer composition of claim 1 , wherein the fill phase comprises 35 wt % or more of the heterophasic propylene copolymer, based on the total weight of the matrix and fill phases.

3. The heterophasic propylene copolymer composition of claim 1 , wherein the matrix phase comprising a melting point (Tm, DSC peak second melt) of at least 100° C.

4. The heterophasic propylene copolymer composition of claim 1 , wherein the matrix phase has a median pore diameter less than 165 um, as determined by mercury intrusion porosimetry.

5. The heterophasic propylene copolymer composition claim 1 , wherein the fill phase comprises a polyolefin having a Tg of −20° C. or less determined by DSC.

6. The heterophasic propylene copolymer composition of claim 1 , wherein the matrix phase has a multimodal molecular weight distribution and an overall molecular weight distribution of 5 or more.

7. The heterophasic propylene copolymer composition of claim 1 , wherein the fill phase of component B) comprises ethylene and from about 3 wt % to 75 wt % of one or more C 3 to C 20 alpha olefins.

8. The heterophasic propylene copolymer composition of claim 1 , wherein the fill phase of component B) has a CDBI of 50% or more.

9. The heterophasic propylene copolymer composition of claim 1 , wherein the copolymer is particulated and at least 95% by volume of the particles has a particle size greater than about 120 um.

10. The heterophasic propylene copolymer composition of claim 1 , said composition having:
1) a total propylene content of at least 75 wt %;
2) a total co-monomer content from about 3 wt % up to about 25 wt %;
3) a CDBI of at least 60%;
4) a fill phase content of 35 wt % or more, based on the total weight of the matrix and fill phases;
5) a matrix median pore diameter greater than 6 um and less than 160 um, as determined by mercury intrusion porosimetry;
6) at least 50% isotactic pentads;
7) more than 10 regio defects per 10,000 propylene units, determined by 13 C NMR;
8) a 1% Secant flexural modulus of greater than about 300 MPa;
9) a matrix phase having a melting point (Tm, DSC peak second melt) of at least 120° C.;
10) a fill phase having a Tg of −30° C. or less determined by DSC;
11) a heat of fusion (Hf, DSC second heat) of 60 J/g or more;
12) at least 95% by volume having a particle size greater than 150 um up to 10 mm;
13) a melt flow rate (MFR, ASTM 1238, 230° C., 2.16 kg) from about 0.1 dg/min up to about 300 dg/min; and
14) an Mw (as measured by GPC-DRI) from 50,000 to 1,000,000 g/mol.

Assignees

• Exxonmobil Chemical Patents Inc

Inventors

• Luo Lubin
• Day Gregory S
• Holtcamp Matthew W

Classifications

• C08L23/24

  having ten or more carbon atoms · CPC title

• C08F2500/15

  Isotactic · CPC title

• C08L23/12 Primary

  Polypropene · CPC title

• C08L2207/02

  Heterophasic composition · CPC title

• C08F4/65912

  in combination with an organoaluminium compound · CPC title