WO2021188361A1 - Linear alpha-olefin copolymers and impact copolymers thereof - Google Patents

Linear alpha-olefin copolymers and impact copolymers thereof Download PDF

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Publication number
WO2021188361A1
WO2021188361A1 PCT/US2021/021949 US2021021949W WO2021188361A1 WO 2021188361 A1 WO2021188361 A1 WO 2021188361A1 US 2021021949 W US2021021949 W US 2021021949W WO 2021188361 A1 WO2021188361 A1 WO 2021188361A1
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copolymer
olefin
linear
kpa
group
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PCT/US2021/021949
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French (fr)
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Carlos R. LOPEZ-BARRON
Tzu-Pin Lin
Avery SMITH
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Exxonmobil Chemical Patents Inc.
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Publication of WO2021188361A1 publication Critical patent/WO2021188361A1/en

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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08FMACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F210/00Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F210/14Monomers containing five or more carbon atoms
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08FMACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2420/00Metallocene catalysts
    • C08F2420/02Cp or analog bridged to a non-Cp X anionic donor
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08FMACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00Polymerisation catalysts
    • C08F4/42Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/62Refractory metals or compounds thereof
    • C08F4/64Titanium, zirconium, hafnium or compounds thereof
    • C08F4/659Component covered by group C08F4/64 containing a transition metal-carbon bond
    • C08F4/65908Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+

Definitions

  • the present disclosure relates to copolymers comprising C 6 -C 60 linear ⁇ -olefin units; diene units; and optionally C 2 -C 10 ⁇ -olefin comonomer units different than the C 6 -C 60 linear ⁇ -olefin units, impact copolymers prepared from such copolymers and process to produce the same.
  • Impact copolymers have a myriad of uses, such as roofing materials, tires, seals, and gaskets. ICPs are characterized as having a rubber phase (“dispersed phase”) dispersed in a continuous phase.
  • ethylene-propylene copolymers are used as the rubber phase in ICPs.
  • ICPs having certain properties, such as a relatively low elastic modulus, which often involves incorporating relatively large amounts of ethylene-propylene (EP) rubber and/or solvent/oil into the impact copolymer.
  • EP ethylene-propylene
  • the lower limit of elastic modulus is ultimately determined by the modulus of the rubber, and the desired modulus of the rubber can achieved by the addition of solvent/oil into at least the rubber phase of the ICP.
  • repeated compression of the ICP during use can squeeze the solvent/oil out of the ICP, resulting in an ICP having compromised compressive strength and elastic properties.
  • hysteresis can be a parameter to examine when assessing a material's impact properties.
  • Hysteresis refers to the energy absorbed when a material is being stretched and the energy that is released when the force is removed.
  • Hysteresis can be an important parameter with tires which increase in pressure during revolution of the wheels. If the tire is underinflated, a ‘blow-out’ can occur.
  • a stress–strain graph for materials such as rubber shows that the behavior as a load (that has been applied to the material) is removed is not the same as the behavior when the load applied to the material is being increased. This difference is referred to as hysteresis, and the curves of the graph are said to form a hysteresis loop.
  • tensile set can be a parameter to examine when assessing a material’s impact properties. Tensile set is the extension remaining after a material has been stretched and then allowed to retract, expressed as a percentage of the original length. The material’s ability (or not) to return to its size before stretching is referred to as its tensile set. Tensile set can be important to many commercial rubber products that expand and contract during normal use.
  • a copolymer has about 50 wt% to about 99.9 wt% C 6 -C 60 linear ⁇ -olefin units, based on the weight of the copolymer; diene units; and optionally C 2 -C 10 ⁇ -olefin comonomer units different than the C 6 -C 60 linear ⁇ -olefin units.
  • a crosslinked copolymer has: a tensile set @ 200% deformation of about 0.1% to about 50% or less; a tensile strength at 40°C of about 50 kPa to about 1,000 kPa; an Edis of about 1 kJ/m 3 to about 10 kJ/m 3 ; an elongation at break of about 10% to about 1,000%; a Young’s modulus (at 40°C) of about 50 kPa to about 1,000 kPa; a glass transition temperature (Tg) of about –100°C to about 0°C; a melting temperature (Tm) of about 50°C to about 150°C; and a temperature of crystallization (Tc) of about 10°C to about 150°C.
  • an impact copolymer includes from 10 wt% to 80 wt% of a copolymer having about 50 wt% to about 99.9 wt% C 6 -C 60 linear ⁇ -olefin units, based on the weight of the copolymer; diene units; and optionally C 2 -C 10 ⁇ -olefin comonomer units different than the C 6 -C 60 linear ⁇ -olefin units; based on the weight of the impact copolymer; and a polypropylene.
  • an article includes an impact copolymer.
  • a process to produce an impact copolymer includes combining a first component comprising polypropylene with from 10 wt% to 80 wt% of a copolymer having about 50 wt% to about 99.9 wt% C 6 -C 60 linear ⁇ -olefin units, based on the weight of the copolymer; diene units; and optionally C 2 -C 10 ⁇ -olefin comonomer units different than the C 6 -C 60 linear ⁇ -olefin units, under melt conditions to form a homogenous melt mixture.
  • a process to produce a copolymer includes introducing a C 6 -C 60 linear ⁇ -olefin, a diene, and optionally C 2 -C 10 ⁇ -olefin comonomer (different than the C 6 -C 60 linear ⁇ -olefin) to a catalyst system comprising an activator and a tetrahydroindacenyl catalyst compound.
  • FIG.1 is a graph illustrating cure kinetics at 160°C of AOEDM samples mixed with 1 phr of DCP, according to at least one embodiment.
  • FIG.2 is a graph illustrating cure kinetics at 160°C of AOEDM samples mixed with 2 phr of sulfur, according to at least one embodiment.
  • FIG.3 is a graph illustrating cure kinetics of Example 6 with three different curing systems, according to at least one embodiment.
  • FIG. 4A is a DSC thermogram DEDM Example 20 uncured and cured with DCP and sulfur, according to at least one embodiment (cooling).
  • FIG 4B is a DSC thermogram DEDM Example 20 uncured and cured with DCP and sulfur, according to at least one embodiment (heating).
  • FIG. 5 is DSC thermograms of ODE (Example 9) and ODEDM (Example 11 and Example 12) samples (uncured), according to at least one embodiment.
  • FIG.6 is DSC thermograms of ODEDM (Example 24) uncured and cured samples, according to at least one embodiment.
  • FIG. 7 is a graph illustrating tensile test of DCP-cured DEDM (Example 20) and ODEDM (Example 24) samples measured at 25°C and 40°C, according to at least one embodiment.
  • FIG. 23 is a graph illustrating tensile test of DCP-cured DEDM (Example 20) and ODEDM (Example 24) samples measured at 25°C and 40°C, according to at least one embodiment.
  • FIG. 8 is a graph illustrating hysteresis test in of DCP-cured ODEDM (Example 24) sample measured at 40°C, according to at least one embodiment.
  • FIG. 9A is a graph illustrating compressive stress-strain curves of DCP-cured ODEDM (Example 24) with 0.32 phr of DCP curative, according to at least one embodiment.
  • FIG. 9B is a graph illustrating compressive stress-strain curves of DCP-cured ODEDM (Example 24) with 1 phr of DCP curative, according to at least one embodiment.
  • FIG. 9A is a graph illustrating compressive stress-strain curves of DCP-cured ODEDM (Example 24) with 0.32 phr of DCP curative, according to at least one embodiment.
  • FIG. 9B is a graph illustrating compressive stress-strain curves of DCP-cured ODEDM (Example 24) with 1 phr of DCP curative, according
  • FIG. 9C is a graph illustrating compressive stress-strain curves of DCP-cured ODEDM (Example 24) with 3.2 phr of DCP curative, according to at least one embodiment.
  • FIG. 10A is a graph illustrating maximum stress (kPA) versus maximum strain % of DCP-cured ODEDM (Example 24), according to at least one embodiment.
  • FIG.10B is a graph illustrating compressive set versus maximum strain % of DCP- cured ODEDM (Example 24), according to at least one embodiment.
  • FIG.10C is a graph illustrating E dis (kJ/m 3 ) versus maximum strain % of DCP-cured ODEDM (Example 24), according to at least one embodiment.
  • DETAILED DESCRIPTION [0030] The present disclosure generally relates to linear ⁇ -olefin-diene copolymers. Copolymers of the present disclosure can be terpolymers including ethylene units. It has been discovered that ethylene units provide spacing between bulkier units of the terpolymer (such as linear ⁇ -olefin units and diene units). The linear ⁇ -olefin-diene copolymers of the present disclosure can be formed by polymerization using tetrahydroindacenyl catalysts.
  • linear ⁇ -olefin-diene copolymers of the present disclosure can have low hysteresis behavior and/or low tensile set. For example, commercial copolymers can have a tensile set of at least 20%.
  • linear ⁇ -olefin-diene copolymers of the present disclosure may have a tensile set of less than 20%, such as less than 15%.
  • Linear ⁇ -olefin-diene copolymers described herein may be suitable for use in, for example, a rubber phase of an ICP.
  • the rubber phase can have less (if any) solvent/oil, as compared to conventional ICPs.
  • conventional ICPs can have, for example, 150 phr of oil.
  • copolymers (rubber phases thereof and ICPs thereof) of the present disclosure can be substantially (e.g., completely) free of oil.
  • solvent/oil that is optionally present in a copolymer/rubber phase of the present disclosure is less prone to being squeezed out during use.
  • low hysteresis behavior and/or low tensile set can be achieved by the linear ⁇ -olefin-diene copolymers disclosed herein without sacrificing impact properties, such as strain hardening properties. Strain hardening is a desirable property in elastomers because it enables the polymers to resist high loads and without penalizing their physical integrity due to repeated loading-unloading deformation cycles and during physical impact(s) during the ICP’s use.
  • compositions comprising “A and/or B” may comprise A alone, B alone, or both A and B; and a composition comprising “A and or B” may comprise A alone, or both A and B.
  • percentage of a particular monomer in a polymer is expressed herein as weight percent (wt%) based on the total weight of the polymer present. All other percentages are expressed as weight percent (wt%), based on the total weight of the particular composition present, unless otherwise noted.
  • Room temperature is 25°C ⁇ 2°C and atmospheric pressure is 101.325 kPa unless otherwise noted.
  • a “polymer” refers to a compound having two or more “mer” units, that is, a degree of polymerization of two or more, where the mer units can be of the same or different species.
  • a “homopolymer” is a polymer having mer units that are the same species.
  • a “copolymer” is a polymer having two or more different species of mer units.
  • a “terpolymer” is a polymer having three different species of mer units.
  • “Different” in reference to mer units indicates that the mer units differ from each other by at least one atom or are different isomerically.
  • reference to a polymer herein includes a copolymer, a terpolymer, or any polymer comprising a plurality of the same or different species of repeating units.
  • the term impact copolymer refers to a thermoplastic resin comprising an elastomeric polymer, often referred to as a rubber, dispersed within a polyolefin continuous phase, e.g., polypropylene.
  • Impact copolymers are suitable for transformation by various processing technologies including injection molding, blow molding, film, fiber, sheet extrusion, thermoforming, and the like.
  • An “impact copolymer” may include uncrosslinked components and/or crosslinked components. When one or more components of the impact copolymer are crosslinked (such as a crosslinked linear ⁇ -olefin-diene copolymer), the impact copolymer may be referred to as a thermoplastic vulcanizate.
  • the prefixes di- and tri- generally refer to two and three, respectively.
  • the prefix “poly-” generally refers to two or more
  • the term “residue” or “unit”, as used herein, means the organic structure of the monomer in its as-polymerized form as incorporated into a polymer, e.g., through polymerization of the corresponding monomer. Throughout the specification and claims, reference to the monomer(s) in the polymer is understood to mean the corresponding as- polymerized form or residue of the respective monomer. [0040] For purposes herein, the melting temperature, crystallization temperature, glass transition temperature, etc., are determined by DSC analysis from the second heating ramp by heating of the sample at 10°C/min from 0°C to 300°C.
  • proton NMR spectra are collected using a suitable instrument, e.g., a 500 MHz Varian pulsed Fourier transform NMR spectrometer equipped with a variable temperature proton detection probe operating at 120°C.
  • Typical measurement of the NMR spectrum include dissolving of the polymer sample in 1,1,2,2-tetrachloroethane-d2 (“TCE-d2”) and transferring into a 5 mm glass NMR tube.
  • Typical acquisition parameters are sweep width of 10 KHz, pulse width of 30 degrees, acquisition time of 2 seconds, acquisition delay of 5 seconds and number of scans was 120.
  • the herein, average particle size of the dispersed phase within the continuous phase of the composition is determined using atomic force microscopy (AFM) unless otherwise specified.
  • Atomic force microscopy is carried out using a Bruker ICON Atomic Force Microscope or the like.
  • Typical analysis involves the cryo-microtoming of the sample prior to scanning in order to create a smooth surface at -80°C. After microtoming, the samples are purged under N2 in a desiccator before AFM evaluation. Imaging is typically conducted by tuning to the fundamental (1st) mode of the cantilever, setting the amplitude at 1.0 V and the drive frequency to about 5% below the free-air resonance frequency of the cantilever. Calibration is conducted using suitable standards, e.g., Asylum Research reference standard (10 microns x 10 microns pitch grating x 200 nm deep pits) for AFM SQC and X, Y, and Z calibration.
  • suitable standards e.g., Asylum Research reference standard (10 microns x 10 microns pitch grating x 200 nm deep pits) for AFM SQC and X, Y, and Z calibration.
  • an “olefin,” alternatively referred to as “alkene,” is a linear, branched, or cyclic compound of carbon and hydrogen having at least one carbon-carbon double bond.
  • alkene is a linear, branched, or cyclic compound of carbon and hydrogen having at least one carbon-carbon double bond.
  • the olefin present in such polymer or copolymer is the polymerized form of the olefin.
  • a copolymer when a copolymer is said to have an “ethylene” content of 35 wt% to 55 wt%, it is understood that the mer unit in the copolymer is derived from ethylene in the polymerization reaction and said derived units are present at 35 wt% to 55 wt%, based upon the weight of the copolymer.
  • a “polymer” has two or more of the same or different mer units.
  • a “homopolymer” is a polymer having mer units that are the same.
  • a “copolymer” is a polymer having two or more mer units that are different from each other.
  • a “terpolymer” is a polymer having three mer units that are different from each other.
  • ethylene polymer or “ethylene copolymer” is a polymer or copolymer comprising at least 50 mol% ethylene derived units
  • ethylene copolymer is a polymer or copolymer comprising at least 50 mol% propylene derived units, and so on.
  • ethylene shall be considered an ⁇ -olefin.
  • hydrocarbyl radical is defined to be a radical, which contains hydrogen atoms and up to 50 carbon atoms and which may be linear, branched, or cyclic, and when cyclic, aromatic or non- aromatic.
  • Examples of a substituted hydrocarbyls would include -CH 2 CH 2 -O- CH3 and –CH2-NMe2 where the radical is bonded via the carbon atom, but would not include groups where the radical is bonded through the heteroatom such as –OCH2CH3 or –NMe2.
  • Silylcarbyl radicals are radicals in which one or more hydrocarbyl hydrogen atoms have been substituted with at least one SiR*3 containing group or where at least one –Si(R*)2- has been inserted within the hydrocarbyl radical where R* is independently a hydrocarbyl or halocarbyl radical, and two or more R* may join together to form a substituted or unsubstituted saturated, partially unsaturated or aromatic cyclic or polycyclic ring structure.
  • Germylcarbyl radicals are radicals in which one or more hydrocarbyl hydrogen atoms have been substituted with at least one GeR* 3 containing group or where at least one –Ge(R*) 2 - has been inserted within the hydrocarbyl radical where R* independently a hydrocarbyl or halocarbyl radical, and two or more R* may join together to form a substituted or unsubstituted saturated, partially unsaturated or aromatic cyclic or polycyclic ring structure.
  • Substituted germylcarbyl radicals are only bonded via a carbon or germanium atom.
  • Halocarbyl radicals are radicals in which one or more hydrocarbyl hydrogen atoms have been substituted with at least one halogen (e.g. F, Cl, Br, I) or halogen-containing group (e.g. CF 3 ).
  • halogen e.g. F, Cl, Br, I
  • halogen-containing group e.g. CF 3
  • R* may join together to form a substituted or unsubstituted saturated, partially unsaturated or aromatic cyclic or polycyclic ring structure.
  • Substituted halocarbyl radicals are only bonded via a carbon atom.
  • a heteroatom is an atom other than carbon or hydrogen.
  • aryl or “aryl group” means a monocyclic or polycyclic aromatic ring and the substituted variants thereof, including but not limited to, phenyl, naphthyl, 2-methyl- phenyl, xylyl, 4-bromo-xylyl.
  • heteroaryl means an aryl group where a ring carbon atom (or two or three ring carbon atoms) has been replaced with a heteroatom, such as N, O, or S.
  • substituted aryl means: 1) an aryl group where a hydrogen has been replaced by a substituted or unsubstituted hydrocarbyl group, a substituted or unsubstituted halocarbyl group, a substituted or unsubstituted silylcarbyl group, or a substituted or unsubstituted germylcarbyl group.
  • substituted heteroaryl means: 1) a heteroaryl group where a hydrogen has been replaced by a substituted or unsubstituted hydrocarbyl group, a substituted or unsubstituted halocarbyl group, a substituted or unsubstituted silylcarbyl group, or a substituted or unsubstituted germylcarbyl group.
  • substituted or unsubstituted hydrocarbyl group a substituted or unsubstituted halocarbyl group
  • substituted or unsubstituted silylcarbyl group or a substituted or unsubstituted germylcarbyl group.
  • Mn is number average molecular weight
  • Mw is weight average molecular weight
  • Mz is z average molecular weight
  • wt% is weight percent
  • mol% is mole percent.
  • Molecular weight distribution (MWD) also referred to as polydispersity, is defined to be Mw divided by Mn. Unless otherwise noted, all molecular weight units (e.g., Mw, Mn, Mz) are g/mol.
  • ENB is 5-ethylidene-2-norbornene
  • Me is methyl
  • Et is ethyl
  • Pr is propyl
  • cPr is cyclopropyl
  • nPr is n-propyl
  • iPr is isopropyl
  • Bu is butyl
  • nBu is normal butyl
  • iBu is isobutyl
  • sBu is sec-butyl
  • tBu is tert-butyl
  • Oct octyl
  • Ph is phenyl
  • Bn is benzyl
  • Cp is cyclopentadienyl
  • Ind is indenyl
  • MAO is methylalumoxane.
  • a “catalyst system” is the combination of at least one catalyst compound, at least one activator, an optional co-activator, and an optional support material.
  • catalyst systems are described as comprising neutral stable forms of the components, it is well understood by one of ordinary skill in the art, that the ionic form of the component is the form that reacts with the monomers to produce polymers.
  • the metallocene catalyst may be described as a catalyst precursor, a pre-catalyst compound, metallocene catalyst compound or a transition metal compound, and these terms are used interchangeably.
  • a metallocene catalyst is defined as an organometallic transition metal compound with at least one ⁇ -bound cyclopentadienyl moiety (or substituted cyclopentadienyl moiety) bound to a transition metal.
  • substituted means that one or more hydrogen atoms have been replaced with a hydrocarbyl, heteroatom (such as a halide), or a heteroatom containing group, (such as silylcarbyl, germylcarbyl, halocarbyl, etc.).
  • alkyl group is a C 1 to C 10 hydrocarbyl.
  • the alkyl group may be straight chain, branched, or cyclic.
  • the alkyl group may be saturated or unsaturated.
  • the alkyl group may comprise at least one aromatic group.
  • Copolymers of the present disclosure comprise a linear ⁇ -olefin, a diene, and optionally a C 2 -C 10 ⁇ -olefin comonomer different than the C 6 -C 60 linear ⁇ -olefin (such as ethylene).
  • “Different” in reference to linear ⁇ -olefins indicates that the linear ⁇ -olefin units differ from each other by at least one atom or are different isomerically.
  • a copolymer has a linear ⁇ -olefin, a diene, and optionally ethylene.
  • a copolymer may have greater than or equal to about 50 wt% and less than or equal to about 99.9 wt% C 6 -C 60 linear ⁇ -olefin, based on the total weight of the copolymer.
  • a copolymer can have a linear ⁇ -olefin content of about 50 wt% to about 99.9 wt%, such as about 60 wt% to about 99.9 wt%, such as from about 70 wt% to about 99.9 wt%, such as from about 80 wt% to about 99.5 wt%, such as from about 85 wt% to about 99 wt%, such as from about 90 wt% to about 99 wt%, such as from about 93 wt% to about 99 wt%, such as from about 95 wt% to about 99 wt%, based on the weight of the copolymer.
  • Linear alpha olefins can be substituted or unsubstituted C 6 -C 60 LAOs, such as C 8 -C 50 LAOs, such as C 10 -C 40 LAOs, such as C 12 -C 30 LAOs, such as C 14 -C 26 LAOs, such as C 16 –C 26 LAOs, such as C 18 -C 26 LAOs, such as C 20 -C 26 LAOs.
  • LAOs can have some branching.
  • an LAO may have one or more pendant methyl or ethyl substitutions along the LAO backbone.
  • an LAO is free of branching, e.g. is entirely linear.
  • a copolymer has linear ⁇ -olefin units selected from 1-octene, 1-decene, 1-undecene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene, 1-icosene, 1-henicosene, 1-docosene, 1-tricosene, 1-tetracosene, 1-pentacosene, and combination(s) thereof.
  • a copolymer can have a diene content of about 0.1 wt% to about 40 wt%, such as from about 0.1 wt% to about 30 wt%, such as from about 0.1 wt% to about 20 wt%, such as from about 0.1 wt% to about 10 wt%, such as from about 0.5 wt% to about 10 wt%, such as from about 1 wt% to about 10 wt%, such as from about 1.5 wt% to about 8 wt%, such as from about 2 wt% to about 6 wt%, such as from about 2 wt% to about 5 wt%, such as from about 3 wt% to about 5 wt%, based on the weight of the copolymer.
  • Dienes can be substituted or unsubstituted dienes selected from C 4 -C 60 dienes, such as C 5 -C 50 dienes, such as C 5 -C 40 dienes, such as C 5 -C 30 dienes, such as C 5 -C 20 dienes, such as C6-C15 dienes, such as C6-C10 dienes, such as C 7 -C 9 dienes, such as a substituted or unsubstituted C 7 diene, C 8 diene, or C 9 diene.
  • a copolymer has diene units of a C7 diene.
  • a diene is a substituted or unsubstituted ⁇ , ⁇ -diene (e.g., the diene units of the copolymer are formed from di-vinyl monomers).
  • the dienes can be linear di-vinyl monomers.
  • a diene is selected from butadiene, pentadiene, hexadiene, heptadiene, octadiene, nonadiene, decadiene, undecadiene, dodecadiene, tridecadiene, tetradecadiene, pentadecadiene, hexadecadiene, heptadecadiene, octadecadiene, nonadecadiene, icosadiene, heneicosadiene, docosadiene, tricosadiene, tetracosadiene, pentacosadiene, hexacosadiene, heptacosadiene, octacosadiene, nonacosadiene, triacontadiene, and combination(s) thereof.
  • a diene is selected from 1,6-heptadiene, 1,7-octadiene, 1,8-nonadiene, 1,9-decadiene, 1,10-undecadiene, 1,11-dodecadiene, 1,12-tridecadiene, 1,13-tetradecadiene, and combination(s) thereof.
  • a diene is selected from cyclopentadiene, vinylnorbornene, norbornadiene, 5-ethylidene-2-norbornene, 5-vinyl-2- norbornene, divinylbenzene, dicyclopentadiene, and combination(s) thereof.
  • a copolymer has diene units of 5-ethylidene-2-norbornene.
  • a copolymer can have C 2 -C 10 ⁇ -olefin comonomer content (different than the C 6 -C 60 linear ⁇ -olefin content) of about 0.1 wt% to about 40 wt%, such as from about 0.1 wt% to about 30 wt%, such as from about 0.1 wt% to about 20 wt%, such as from about 1 wt% to about 15 wt%, such as from about 1 wt% to about 10 wt%, such as from about 1.5 wt% to about 9 wt%, such as from about 2 wt% to about 8 wt%, such as from about 1.5 wt% to about 2.5 wt%, alternatively from about 8 wt% to about 15 wt%, such as from about 8 wt% to about 12 wt%,
  • a copolymer has one or more of: an Mw value of 5,000 g/mol or greater, such as from about 10,000 g/mol to about 2,000,000 g/mol, such as from about 50,000 g/mol to about 2,000,000 g/mol, such as from about 100,000 g/mol to about 1,000,000 g/mol, such as from about 100,000 g/mol to about 500,000 g/mol, such as from about 150,000 g/mol to about 300,000 g/mol, such as from about 200,000 g/mol to about 300,000 g/mol, alternatively from about 400,000 g/mol to 500,000 g/mol; an Mn value of 5,000 g/mol or greater, such as from about 5,000 to about 1,000,000, such as about 40,000 g/mol to about 300,000 g/mol, such as from about 60,000 g/mol to about 250,000 g/mol, such as from about 70,000 g/mol to about 200,000 g/mol, such as from about 80,000
  • the copolymer has an Mw/Mn (MWD) value of 1 to 10, such as from 1 to 5, such as from 1.5 to about 4, such as from 2 to about 3.
  • the copolymer has a glass transition temperature (Tg) of -30°C or less, such as from about -30°C to about -100°C, such as from about -50°C to about -70°C.
  • the copolymer has a crystallization temperature (Tc) of at least 0°C, such as from about 0°C to about 100°C, such as from about 20°C to about 80°C, such as from about 60°C to about 80°C.
  • the distribution and the moments of molecular weight (Mw, Mn, Mz, Mw/Mn, etc.), the comonomer content and the branching index (g') are determined by using a high temperature Gel Permeation Chromatography (Polymer Char GPC-IR) equipped with a multiple-channel band-filter based Infrared detector IR5 with a multiple-channel band filter based infrared detector ensemble IR5 with band region covering from about 2,700 cm -1 to about 3,000 cm -1 (representing saturated C-H stretching vibration), an 18-angle light scattering detector and a viscometer.
  • Polymer Char GPC-IR Polymer Char GPC-IR
  • the oligomer or polymer may automatically be dissolved in the instrument with ⁇ 8 mL added TCB solvent at ⁇ 160°C with continuous shaking.
  • the sample solution concentration can be from ⁇ 0.2 mg/ml to ⁇ 2.0 mg/ml, with lower concentrations used for higher molecular weight samples.
  • the mass recovery can be calculated from the ratio of the integrated area of the concentration chromatography over elution volume and the injection mass which is equal to the pre- determined concentration multiplied by injection loop volume.
  • the conventional molecular weight (IR MW) is determined by combining universal calibration relationship with the column calibration which is performed with a series of monodispersed polystyrene (PS) standards ranging from 700 to 10M gm/mole.
  • PS monodispersed polystyrene
  • ⁇ PS 0.7362
  • KPS 0.0000957
  • ⁇ and K for other materials are as calculated and published in literature (Sun, T. et al.
  • the comonomer composition is determined by the ratio of the IR5 detector intensity corresponding to CH2 and CH3 channel calibrated with a series of PE and PP homo/copolymer standards whose nominal value are predetermined by NMR or FTIR. In particular, this provides the methyls per 1,000 total carbons (CH3/1000TC) as a function of molecular weight.
  • the short-chain branch (SCB) content per 1000TC (SCB/1000TC) is then computed as a function of molecular weight by applying a chain-end correction to the CH3/1000TC function, assuming each chain to be linear and terminated by a methyl group at each end.
  • the LS detector is the 18-angle Wyatt Technology High Temperature DAWN HELEOSII.
  • the LS molecular weight (M) at each point in the chromatogram is determined by analyzing the LS output using the Zimm model for static light scattering (Light Scattering from Polymer Solutions; Huglin, M. B., Ed.; Academic Press, 1972.): K o c 1 ⁇ ⁇ 2A 2 c .
  • ⁇ R( ⁇ ) is the em easured excess Ray leigh scattering intensity at scattering angle ⁇
  • c is the polymer concentration determined from the IR5 analysis
  • a 2 is the second virial coefficient
  • P( ⁇ ) is the form factor for a monodisperse random coil
  • K o is the optical constant for the system: 4 ⁇ 2n2(dn/dc ) 2 K o ⁇ ⁇ 4 N where N A is Avogadro’s number, and (dn/dc) is the refractive index increment for the system.
  • a high temperature Agilent (or Viscotek Corporation) viscometer which has four capillaries arranged in a Wheatstone bridge configuration with two pressure transducers, is used to determine specific viscosity.
  • One transducer measures the total pressure drop across the detector, and the other, positioned between the two sides of the bridge, measures a differential pressure.
  • the specific viscosity, ⁇ s for the solution flowing through the viscometer is calculated from their outputs.
  • the intrinsic viscosity, [ ⁇ ] ⁇ s /c, where c is concentration and is determined from the IR5 broadband channel output.
  • the viscosity MW at each point is calculated asM ⁇ K PS M ⁇ PS ⁇ 1 [ ⁇ ] , where ⁇ ps is 0.67 and Kps is 0.000175.
  • the branching index (g' vis ) is calculated using the output of the GPC-IR5-LS-VIS method as follows.
  • the average intrinsic viscosity, [ ⁇ ] avg , of the sample is calculated by: c [ ⁇ ] i ⁇ ⁇ ⁇ i avg ⁇ ⁇ ⁇ where the summations are over the chromatographic slices, i, between the integration limits.
  • the linear ⁇ -olefin-diene copolymers can be vulcanized by employing a variety of curatives to form crosslinked copolymers.
  • curatives can include ultraviolet cure, sulfur cure systems, phenolic resin cure systems, peroxide cure systems, silicon-containing cure systems, such as hydrosilylation and silane grafting / moisture cure.
  • Dynamic vulcanization can occur in the presence of the polyolefin (of a continuous phase), or the polyolefin can be added after dynamic vulcanization (e.g., post added), or both (e.g., some polyolefin can be added prior to vulcanization and some polyolefin can be added after vulcanization).
  • Vulcanization can be effected by mixing the copolymer, optional polyolefin (e.g., polypropylene), and curative(s) at elevated temperature in conventional mixing equipment such as roll mills, stabilizers, Banbury mixers, Brabender mixers, continuous mixers, mixing extruders and the like.
  • TPV compositions for example, are described in US Pat. Nos.4,311,628, 4,594,390, 6,503,984, and 6,656,693 (which are incorporated herein by reference), although methods employing low shear rates can also be used. Multiple-step processes can also be employed whereby ingredients, such as additional thermoplastic component (polyolefin), can be added after dynamic vulcanization has been achieved as disclosed in International Application No. PCT/US2004/030517, which is incorporated herein by reference.
  • a process for the preparation of the TPV composition (and/or ICP composition) can include melt processing under shear conditions of at least one thermoplastic component, at least one rubber component, and at least one curing agent.
  • the melt processing can be performed under high shear conditions.
  • Shear conditions are similar to conditions that exist when the TPV compositions (and/or ICP compositions) are produced using common melt processing equipment such as Brabender or Banbury mixers (lab scale instruments) and commercial twin-screw extruders.
  • the word shear is added to indicate that the TPV compositions (and/or ICP compositions) can be made by mixing under high shear temperature and intense mixing.
  • the TPV (or ICP) compositions are dynamically vulcanized by a variety of methods including employing a cure system, where the cure system comprises a curative.
  • useful peroxide curatives can include organic peroxides.
  • organic peroxides can include di-tert-butyl peroxide, dicumyl peroxide, t-butylcumyl peroxide, ⁇ , ⁇ -bis(tert-butylperoxy) diisopropyl benzene, 2,5-dimethyl-2,5-di(t- butylperoxy)hexane (DBPH), 1,1-di(tert-butylperoxy)-3,3,5-trimethyl cyclohexane, n-butyl-4- 4-bis(tert-butylperoxy) valerate, benzoyl peroxide, lauroyl peroxide, dilauroyl peroxide, 2,5-dimethyl-2,5-di(tert-butylperoxy) hexyne-3, and mixtures thereof.
  • DBPH 2,5-dimethyl-2,5-di(t- butylperoxy)hexane
  • DBPH 2,5-dimethyl-2,
  • diaryl peroxides, ketone peroxides, peroxydicarbonates, peroxyesters, dialkyl peroxides, hydroperoxides, peroxyketals and mixtures thereof may be used.
  • Useful peroxides and their methods of use in vulcanization are disclosed in US Pat. No. 5,656,693, which is incorporated herein by reference.
  • the peroxide curatives can be employed in conjunction with a coagent.
  • coagents can include triallylcyanurate, triallyl isocyanurate, triallyl phosphate, sulfur, N-phenyl bis-maleamide, zinc diacrylate, zinc dimethacrylate, divinyl benzene, 1,2-polybutadiene, trimethylol propane trimethacrylate, tetramethylene glycol diacrylate, trifunctional acrylic ester, dipentaerythritolpentacrylate, polyfunctional acrylate, retarded cyclohexane dimethanol diacrylate ester, polyfunctional methacrylates, acrylate and methacrylate metal salts, and oximes such as quinone dioxime.
  • the mixing and dynamic vulcanization may be carried out in a nitrogen atmosphere.
  • a sulfur source may be used to effect crosslinking.
  • sulfur sources include elemental sulfur.
  • a copolymer (or ICP thereof) may undergo crosslinking to form a crosslinked copolymer (or a TPV) at elevated temperatures.
  • the crosslinking may take place at a temperature of about 150°C or greater, such as about 160°C or greater, about 170°C or greater, about 180°C or greater, about 190°C or greater, about 200°C or greater, about 210°C or greater, about 220°C or greater, about 230°C or greater, about 240°C or greater, or about 250°C or greater.
  • crosslinking may be performed by exposing the copolymer (or ICP thereof) to electromagnetic radiation having a frequency greater than that of visible light, such as for example near ultraviolet radiation, extreme ultraviolet radiation, soft x-rays, hard x-rays, gamma rays, and high-energy gamma rays.
  • electromagnetic radiation having a frequency greater than that of visible light
  • crosslinking is accomplished by electron beam radiation, or "e-beam" radiation.
  • E-beam radiation is a form of ionizing energy that is generally characterized by its low penetration and high dose rates.
  • the electrons can be generated by equipment referred to as accelerators which are capable of producing beams that are either pulsed or continuous.
  • beam is meant to include any area exposed to electrons, which may range from a focused point to a broader area, such as a line or field.
  • the electrons are produced by a series of cathodes (electrically heated tungsten filaments) that generate a high concentration of electrons. These electrons are then accelerated across a potential.
  • the accelerating potential is typically in the keV to MeV range (where eV denotes electron volts), depending on the depth of penetration required.
  • Suitable e-beam equipment is available from E-BEAM Services, Inc., or from PCT Engineered Systems, LLC.
  • Effective irradiation is generally carried out at a dosage from about 10 kGy to about 100 kGy, or from about 20 to about 90 kGy, or from about 30 to about 80 kGy, or from about 50 to about 60 kGy. In a particular aspect of this embodiment, the irradiation is carried out at room temperature.
  • a photo-initiator may be added to (e.g., mixed with) the copolymer (or ICP) to promote crosslinking upon exposure to electromagnetic radiation.
  • Suitable photo-initiators include ketones (such as 1-hydroxycyclohexyl phenyl ketone), 2,2-Diethoxyacetophenone, 4′-Hydroxy-3′,5′-dimethylacetophenone, 2,2-Dimethoxy-2-phenylacetophenone, or 1-Benzoylcyclohexanol.
  • the amount of additive (such as peroxide or sulfur source) or photo-initiator (such as a ketone) can be kept low while providing sufficient crosslinking.
  • an amount of additive/photo-initiator can be from about 0.1 wt% to about 10 wt%, such as from about 0.5 wt% to about 5 wt%, such as from about 1 wt% to about 3 wt%, based on the weight of the copolymer (or the rubber in the ICP thereof).
  • an amount of additive/photo-initiator can be from about 0.1 pounds per hundred rubber (phr) to about 10 phr, such as from about 0.5 phr to about 5 phr, such as from about 1 phr to about 3 phr, based on the weight of the copolymer (or the rubber in the ICP thereof).
  • the copolymer can be crosslinked to produce finely dispersed rubber domains in a continuous phase.
  • the copolymer is partially or fully (completely) crosslinked before an extrusion stage.
  • a method for determining the degree of crosslinking is disclosed in US Pat. No. 4,311,628, which is incorporated herein by reference.
  • the copolymer has a degree of crosslinking where not more than about 5.9 wt%, such as not more than about 5 wt%, such as not more than about 4 wt%, such as not more than about 3 wt% is extractable by cyclohexane at 23°C as described in US Pat. Nos.
  • the copolymer is crosslinked to an extent where greater than about 94 wt%, such as greater than about 95 wt%, such as greater than about 96 wt%, such as greater than about 97 wt% by weight of the copolymer is insoluble in cyclohexane at 23°C.
  • the copolymer has a degree of cure such that the crosslink density is at least 4 ⁇ 10 ⁇ 5 moles per milliliter of elastomer, such as at least 7 ⁇ 10 ⁇ 5 moles per milliliter of copolymer, such as at least 10 ⁇ 10 ⁇ 5 moles per milliliter of copolymer.
  • the crosslink density is at least 4 ⁇ 10 ⁇ 5 moles per milliliter of elastomer, such as at least 7 ⁇ 10 ⁇ 5 moles per milliliter of copolymer, such as at least 10 ⁇ 10 ⁇ 5 moles per milliliter of copolymer.
  • a “partially vulcanized” copolymer is one where more than 5 weight percent (wt%) of the crosslinkable copolymer is extractable in boiling xylene, subsequent to vulcanization, e.g., crosslinking of the rubber phase of a TPV.
  • wt% weight percent
  • a TPV including a partially vulcanized copolymer at least 5 wt% and less than 20 wt%, or 30 wt%, or 50 wt% of the crosslinkable copolymer can be extractable from the specimen of the TPV in boiling xylene.
  • the copolymer is in the form of a thermoplastic vulcanizate including the crosslinked copolymer and a polyolefin (such as a polypropylene).
  • the copolymer can be in the form of finely-divided and well-dispersed particles of vulcanized or cured copolymer within a continuous phase. In some embodiments, a co-continuous morphology or a phase inversion can be achieved.
  • Crosslinked Copolymers [0099] Tensile properties are measured using an RSA-G2 solids analyzer (TA Instruments). A plaque of copolymer sample with 0.5 mm thickness is molded and cured (vulcanized) using a hot press equilibrated at 160°C. Small dogbone specimens (5 mm X 5 mm) are cut from the cure plaques for the tensile tests. The dogbones are mounted on the RSA- G2 using film-gripping tools, and the temperature is equilibrated to 40°C for 5 minutes, using the RSA-G2 forced-convection oven. Two tensile tests are performed, namely, (1) tensile to break and (2) hysteresis.
  • a crosslinked copolymer can have a tensile set @200% deformation of 50% or less, such as about 40% or less, such as about 20% or less, such as about 5% or less.
  • a crosslinked copolymer can exhibit a tensile set @200% deformation of about 0.1% to about 50%, such as from about 1% to about 30%, such as from about 2% to about 20%, such as from about 3% to about 15%, such as from about 3% to about 10%, such as from about 3% to about 7%.
  • a crosslinked copolymer can have a tensile strength at 40°C of 60 kPa or more, such as about 150 kPa or more, such as about 350 kPa or more, such as about 500 kPa or more.
  • a crosslinked copolymer can exhibit a tensile strength at 40°C of about 50 kPa to about 1,000 kPa, such as from about 100 kPa to about 750 kPa, such as from about 200 kPa to 700 kPa, such as from about 300 kPa to about 700 kPa, such as from about 400 kPa to about 650 kPa.
  • a crosslinked copolymer can have a dissipated energy (E dis ) of 1 kJ/m 3 or more, such as about 10 kJ/m 3 or more, such as about 50 kJ/m 3 or more, such as about 100 kJ/m 3 or more.
  • E dis dissipated energy
  • a crosslinked copolymer can exhibit an E dis of about 1 kJ/m 3 to about 200 kJ/m 3 , such as from about 1 kJ/m 3 to about 150 kJ/m 3 , such as from about 1 kJ/m 3 to 125 kJ/m 3 , such as from about 50 kJ/m 3 to about 125 kJ/m 3 , such as from about 75 kJ/m 3 to about 100 kJ/m 3 .
  • the dissipated energy (E dis ) is computed as the difference between the integrated area of the stress-strain curve corresponding to the loading and the integrated area of the stress-strain curve corresponding to the unloading during one hysteresis cycle.
  • a crosslinked copolymer can have an elongation at break at 23°C of 10% or more, such as about 100% or more, such as about 250% or more, such as about 500% or more.
  • a crosslinked copolymer can exhibit an elongation at break of about 10% to about 1,000%, such as from about 100% to about 900%, such as from about 200% to about 800%, such as from about 300% to about 700%, such as from about 400% to about 600%, such as from about 400% to about 500%, alternatively from about 150% to about 250%.
  • a crosslinked copolymer can exhibit a Young’s modulus (at 40°C) of about 50 kPa or more, such as about 100 kPa or more, such as about 500 kPa or more.
  • the Young’s modulus is defined as the stress measured at 1% strain divided by 100.
  • a crosslinked copolymer can exhibit a Young’s modulus (at 23°C) of about 50 kPa to about 1,000 kPa, such as from about 100 kPa to about 900 kPa, such as from about 200 kPa to about 800 kPa, such as from about 300 kPa to about 700 kPa, such as from about 400 kPa to about 600 kPa, such as from about 500 kPa to about 600 kPa.
  • Tg is measured as the middle temperature at the inflection point measured by DSC.
  • a crosslinked copolymer can have a Tg of about 0°C or less, such as about –25°C or less, such as about –35°C or less, such as about –50°C or less. In at least one embodiment, a crosslinked copolymer can have a Tg of about –100°C to about 0°C, such as from about –80°C to about –25°C, such as from about –70°C to about –35°C, such as from about –70°C to about –60°C.
  • a crosslinked copolymer can have an inherent modulus (Gno) of about 5 kPa to about 1,000 kPa, such as from about 10 kPa to about 500 kPa, such as from about 10 kPa to about 250 kPa, such as from about 20 kPa to about 50 kPa, alternatively from about 200 kPa to about 300 kPa.
  • Gno inherent modulus
  • the curing kinetics can be measured in an ARES-G2 rheometer (TA Instruments).
  • a small sample of the green (uncured) sample can be molded into a disc with 8 mm diameter and 4 mm height.
  • a crosslinked copolymer can have an entanglement molecular weight (M e ) of about 0.003 MPa to about 0.3 MPa.
  • a crosslinked copolymer can have a melting temperature (Tm) of about 50°C to about 150°C, such as from about 70°C to about 130°C, such as from about 90°C to about 110°C, alternatively from about 110°C to about 135°C.
  • Tm melting temperature
  • a crosslinked copolymer can have a temperature of crystallization (Tc) of about 10°C to about 150°C, such as from about 30°C to about 100°C, such as from about 60°C to about 80°C, alternatively from about 10°C to about 35°C.
  • Tc temperature of crystallization
  • an impact copolymer comprises a continuous phase comprising a thermoplastic polymer, such as polypropylene, and from 10 wt% to 80 wt% of a dispersed phase, based on the total amount of the composition, the dispersed phase including a copolymer of a linear ⁇ -olefin, a diene, and optionally C 2 -C 10 ⁇ -olefin comonomer different than the C 6 -C 60 linear ⁇ -olefin.
  • Impact copolymers can include crosslinked copolymers and/or uncrosslinked copolymers of the present disclosure.
  • the dispersed phase includes a linear ⁇ -olefin, a diene, and ethylene copolymer having greater than or equal to about 60 wt% and less than or equal to about 99.9 wt% C 6 -C 60 linear ⁇ -olefin, based on the total weight of the copolymer.
  • the dispersed phase is essentially free of polypropylene.
  • the dispersed phase may include less than 5 wt%, such as less than 1 wt%, such as less than 0.1 wt% polypropylene.
  • the impact copolymer composition includes from about 5 wt% to about 80 wt% of a dispersed phase, such as from about 10 wt% to about 50 wt%, such as from about 10 wt% to about 30 wt%, based on the total amount of the composition.
  • the dispersed phase of the impact copolymer composition also referred to herein as the rubber phase of the impact copolymer composition, includes a linear ⁇ -olefin-diene copolymer.
  • the copolymer can optionally include ethylene.
  • Properties of an impact copolymer may be influenced by the average particle size or domain size of the dispersed phase, along with the interaction of the dispersed phase with the continuous phase. Utilizing a rubber having high compatibility with polypropylene along with a very low modulus results in impact copolymers and other TPOs with improved properties.
  • the well dispersed rubber domains may provide improved toughening characteristics.
  • the average particle size of the dispersed phase is in the range of a few microns.
  • the rubber domain size may be submicron, e.g. less than about 500 nm. In some embodiments, the rubber domain size is from about 100 nm to 500 nm.
  • the rubber domain size is less than or equal to about 100 nm, such as less than or equal to about 75nm, such as less than or equal to about 50 nm, when determined using AFM.
  • the impact copolymer can be made in-reactor, in an extruder, or a combination of the two.
  • Continuous Phase – Polypropylene [0115] As noted above, the continuous phase of an impact copolymer of the present disclosure can be one or more polypropylenes.
  • Polypropylenes also referred to as “propylene- based polymers” include those solid, typically high-molecular weight plastic resins that primarily include units deriving from the polymerization of propylene.
  • At least 75%, in other embodiments at least 90%, in other embodiments at least 95%, and in other embodiments at least 97% of the units of the propylene-based polymer are derived from the polymerization of propylene.
  • a polypropylene may be a propylene homopolymer with little or substantially no comonomer content, such as about 5 wt% or less, about 4 wt% or less, about 1 wt% or less, about 0.5 wt% or less, about 0.1 wt% or less, or about 0.05 wt% or less (substantially no comonomer).
  • a polypropylene is a propylene homopolymer, such as an isotactic propylene homopolymer.
  • Polypropylene homopolymer can include linear chains and/or chains with long chain branching.
  • small amounts (less than 10 wt%) of a comonomer may be used in a polypropylene to obtain desired polymer properties.
  • such copolymers typically contain less than 10 wt%, or less than 6 wt%, or less than 4 wt%, or less than 2 wt%, or less than 1 wt% of comonomer.
  • a polypropylene may also include units deriving from the polymerization of ethylene and/or ⁇ -olefins such as 1-butene, 1-hexene, 1-octene, 2-methyl-1-propene, 3-methyl-1-pentene, 4-methyl-1-pentene, 5-methyl-1-hexene, and mixtures thereof. Specifically included are the reactor, impact, and random copolymers of propylene with ethylene or the higher ⁇ -olefins, described above, or with C10-C20 olefins. [0118] In some embodiments, the polypropylene includes a homopolymer, random copolymer, or impact copolymer polypropylene or combination(s) thereof.
  • the polypropylene is a high melt strength (HMS) long chain branched (LCB) homopolymer polypropylene.
  • HMS high melt strength
  • LCB long chain branched
  • a propylene homopolymer or random copolymer is formed using a process utilizing one or two liquid filled loop reactors in series.
  • the term liquid or bulk phase reactor is intended to encompass a liquid propylene process as described by Ser van Ven in “Polypropylene and Other Polyolefins”, 1990, Elsevier Science Publishing Company, Inc., pp. 119-125.
  • the propylene homopolymer or random copolymer may also be prepared in a gas-phase reactor, a series of gas phase reactors or a combination of liquid filled loop reactors and gas phase reactors in any suitable sequence as described in US Pat. No. 7,217,772, incorporated by reference.
  • a polypropylene may be synthesized by using an appropriate polymerization technique such as Ziegler-Natta type polymerizations, and catalysis employing single-site organometallic catalysts including metallocene catalysts.
  • Propylene based polymer crystallinity and isotacticity and, therefore, the crystallinity and tacticity of a polypropylene can be controlled by the ratio of co-catalyst to electron donor, and the type of co-catalyst/donor system and is also affected by the polymerization temperature.
  • the appropriate ratio of co-catalyst to electron donor is dependent upon the catalyst/donor system selected.
  • Examples of polypropylene suitable for ICP blends may include ExxonMobilTM PP5341 (available from ExxonMobil); AchieveTM PP6282NE1 (available from ExxonMobil) and/or polypropylene resins with broad molecular weight distribution as described in US 9,453,093 and US 9,464,178; and other polypropylene resins described in US 2018/0016414 and US 2018/0051160; additional examples may include Waymax MFX6 (available from Japan Polypropylene Corp.); Borealis DaployTM WB140 (available from Borealis AG); Braskem Ampleo 1025MA and Braskem Ampleo 1020GA (available from Braskem Ampleo); and Sabic PP-UMS HEX17112 or Sabic PP571P (available from SABIC).
  • ExxonMobilTM PP5341 available from ExxonMobil
  • AchieveTM PP6282NE1 available from ExxonMobil
  • the amount of hydrogen used to prepare a polypropylene is dependent in large measure on the donor and catalyst system used.
  • suitable continuous phases include, but are not limited to, homopolymer polypropylene and random ethylene-propylene or random propylene- ⁇ ⁇ -olefin copolymer, where the comonomer includes, but is not limited to, C 4 , C 6 or C 8 ⁇ -olefins or combinations thereof.
  • a polypropylene useful herein includes one or more of the following characteristics: 1) weight average molecular weight (Mw) from about 50,000 g/mol to about 2,000,000 g/mol, such as from about 100,000 g/mol to about 1,000,000 g/mol, from about 100,000 g/mol to about 600,000 g/mol, or from about 400,000 g/mol to about 800,000 g/mol, as measured by gel permeation chromatography (GPC) with polystyrene standards; 2) a number average molecular weight (Mn) from about 25,000 g/mol to about 1,000,000 g/mol, such as from about 50,000 g/mol to about 300,000 g/mol as measured by GPC with polystyrene standards; 3) a Z average molecular weight (Mz) from about 75,000 g/mol to about 3,000,000 g/mol, such as from about 100,000 g/mol to about 2,000,000 g/mol as measured by GPC
  • a polypropylene has a PDI of about 15 or less, about 14 or less, about 13 or less, about 12 or less, about 11 or less, about 10 or less, about 9.5 or less, or about 9 or less. In some embodiments, a polypropylene has a PDI from about 4.5 to about 15, such as from about 4.5 to about 12, from about 5 to about 10, or from about 6 to about 9.
  • these polydispersity indices are obtained in the absence of visbreaking using peroxide or other post reactor treatment designed to reduce molecular weight; 5) an Mz/Mw ratio of about 2.5 or greater, about 2.6 or greater, about 2.7 or greater, about 2.8 or greater, about 2.9 or greater, about 3 or greater, about 3.1 or greater, or about 3.2 or greater.
  • a polypropylene may have an Mz/Mw ratio of about 7 or less, about 6.5 or less, about 6 or less, about 5.5 or less, or about 5 or less; 6) a melting point (Tm) from about 110°C to about 170°C, such as from about 140°C to about 168°C, or from about 160°C to about 165°C, as determined by ISO 11357-1,2,3; 7) a glass transition temperature (Tg) from about -50°C to about 10°C, such as from about -30°C to about 5°C, or from about -20°C to about 2°C, as determined by ISO 11357-1,2,3; 8) a crystallization temperature (Tc) of about 75 °C or more, such as about 95°C or more, about 100°C or more, about 105°C or more, or from about 105°C to about 130°C), as determined by ISO 11357-1,2,3; 9) a melt flow rate (MFR) from about 0.1 g/10
  • the MFR may be determined by ASTM-1238 measured at load of 2.16 kg and 230°C; 10) a heat of fusion (Hf) of about 52.3 J/g or more, such as about 100 J/g or more, about 125 J/g or more, or about 140 J/g or more; 11) a g'vis of about 1 or less, such as about 0.9 or less, about 0.8 or less, about 0.6 or less, or about 0.5 or less.
  • a polypropylene includes a homopolymer of a high- crystallinity isotactic or syndiotactic polypropylene.
  • a polypropylene can have a density of about 0.89 g/cc 3 to about 0.91 g/cc 3 , with the largely isotactic polypropylene having a density of about 0.90 g/cc 3 to about 0.91 g/cc 3 .
  • high and ultra-high molecular weight polypropylene that has a fractional melt flow rate can be employed.
  • polypropylene resins may be characterized by a MFR (ASTM D-1238; 2.16 kg @ 230°C) that is about 10 g/10min or less, such as about 1 g/10min or less, or about 0.5 g/10min or less.
  • Impact copolymers of the present disclosure may include one or more additives.
  • the additives may include reinforcing and non-reinforcing fillers, antioxidants, stabilizers, processing oils (or other solvent(s)), compatibilizing agents, lubricants (e.g., oleamide), antiblocking agents, antistatic agents, waxes, coupling agents for the fillers and/or pigment, pigments, flame retardants, antioxidants, or other processing aids, or combination(s) thereof.
  • lubricants e.g., oleamide
  • antiblocking agents e.g., antistatic agents
  • waxes e.g., oleamide
  • an ICP and/or rubber phase thereof can have less than 150 phr solvent/oil, such as less than 125 phr, such as less than 100 phr, such as less than 50 phr, such as less than 25 phr, such as 0 phr.
  • an ICP and/or rubber phase thereof can be substantially (e.g., entirely) free of solvent/oil.
  • solvent/oil that is optionally present in the rubber phase is less prone to being squeezed out during use.
  • Impact copolymers of the present disclosure can include additives such that the additives (e.g., fillers of the present disclosure (present in a composition) have an average agglomerate size of less than 50 microns, such as less than 40 microns, such as less than 30 microns, such as less than 20 microns, such as less than 10 microns, such as less than 5 microns, such as less than 1 micron, such as less than 0.5 microns, such as less than 0.1 microns, based on a 1cm x 1cm cross section of the impact copolymer as observed using scanning electron microscopy.
  • the impact copolymer may include fillers and coloring agents.
  • Exemplary materials include inorganic fillers such as calcium carbonate, clays, silica, talc, titanium dioxide or carbon black. Any type of carbon black can be used, such as channel blacks, furnace blacks, thermal blacks, acetylene black, lamp black and the like.
  • the impact copolymer may include flame retardants, such as calcium carbonate, inorganic clays containing water of hydration such as aluminum trihydroxides (“ATH”) or Magnesium Hydroxide.
  • the composition may include UV stabilizers, such as titanium dioxide or Tinuvin® XT-850. The UV stabilizers may be introduced into the roofing composition as part of a master-batch.
  • UV stabilizer may be pre-blended into a master-batch with a thermoplastic resin, such as polypropylene, or a polyethylene, such as linear low density polyethylene.
  • a thermoplastic resin such as polypropylene
  • a polyethylene such as linear low density polyethylene.
  • Still other additives may include antioxidant and/or thermal stabilizers.
  • processing and/or field thermal stabilizers may include IRGANOX® B-225 and/or IRGANOX® 1010 available from BASF.
  • the impact copolymer may include a polymeric processing additive.
  • the processing additive may be a polymeric resin that has a very high melt flow index.
  • polymeric resins can include both linear and branched polymers that can have a melt flow rate that is about 500 dg/min or more, such as about 750 dg/min or more, such as about 1000 dg/min or more, such as about 1200 dg/min or more, such as about 1500 dg/min or more.
  • melt flow rate that is about 500 dg/min or more, such as about 750 dg/min or more, such as about 1000 dg/min or more, such as about 1200 dg/min or more, such as about 1500 dg/min or more.
  • Mixtures of various branched or various linear polymeric processing additives, as well as mixtures of both linear and branched polymeric processing additives can be employed.
  • Reference to polymeric processing additives can include both linear and branched additives unless otherwise specified.
  • Linear polymeric processing additives can include polypropylene homopolymers, and branched polymeric processing additives can include diene-modified polypropy
  • the impact copolymer of the present disclosure may optionally include reinforcing and non-reinforcing fillers, antioxidants, stabilizers, rubber processing oil, lubricants, antiblocking agents, anti-static agents, waxes, foaming agents, pigments, flame retardants, nucleating agents, and other processing aids known in the rubber compounding art.
  • These additives can comprise up to about 50 weight percent of the total composition.
  • Fillers and extenders that can be utilized include conventional inorganics such as calcium carbonate, clays, silica, talc, titanium dioxide, carbon black, a nucleating agent, mica, wood flour, and the like, and blends thereof, as well as inorganic and organic nanoscopic fillers.
  • Molded products [0135] The compositions described herein may be used to prepare molded products in any molding process, including but not limited to, injection molding, gas-assisted injection molding, extrusion blow molding, injection blow molding, injection stretch blow molding, compression molding, rotational molding, foam molding, thermoforming, sheet extrusion, and profile extrusion. [0136] Further, the compositions described herein may be shaped into desirable end use articles by any suitable means.
  • Thermoforming is a process of forming at least one pliable plastic sheet into a desired shape.
  • an extrudate film of a composition (and any other layers or materials) is placed on a shuttle rack to hold it during heating.
  • the shuttle rack indexes into the oven which pre-heats the film before forming. Once the film is heated, the shuttle rack indexes back to the forming tool.
  • thermoforming is accomplished by vacuum, positive air pressure, plug-assisted vacuum forming, or combinations and variations of these, once the sheet of material reaches thermoforming temperatures, typically of 140°C to 185°C or higher.
  • a pre-stretched bubble step is used, especially on large parts, to improve material distribution.
  • Blow molding is another suitable forming means for use with a composition described herein, which includes injection blow molding, multi-layer blow molding, extrusion blow molding, and stretch blow molding, and is especially suitable for substantially closed or hollow objects, such as, for example, gas tanks and other fluid containers.
  • Blow molding is described in more detail in, for example, Concise Encyclopedia of Polymer Science and Engineering, pp.90-92 (Jacqueline I. Kroschwitz, ed., John Wiley & Sons 1990).
  • molded articles may be fabricated by injecting molten polymer into a mold that shapes and solidifies the molten polymer into desirable geometry and thickness of molded articles.
  • Non-woven and Fiber products may be made either by extruding a substantially flat profile from a die, onto a chill roll, or by calendaring.
  • the compositions described herein may be used to prepare nonwoven fabrics and fibers in any nonwoven fabric and fiber making process, including but not limited to, melt blowing, spun-bonding, film aperturing, and staple fiber carding. Examples include continuous filament processes, spun-bonding processes, and the like.
  • the spun-bonding process involves the extrusion of fibers through a spinneret. These fibers are then drawn using high velocity air and laid on an endless belt.
  • a calender roll is generally then used to heat the web and bond the fibers to one another although other techniques may be used such as sonic bonding and adhesive bonding.
  • copolymer composition according to embodiments disclosed herein are useful in a wide variety of applications where a low elastic modulus, low hysteresis and tensile set is desired.
  • automotive overshoot parts e.g., door handles and skins such as dashboard, instrument panel and interior door skins
  • house tool handles e.g., house tool handles, airbag covers, toothbrush handles, shoe soles, grips, skins, toys, appliance moldings and fascia, gaskets, furniture moldings and the like.
  • Other articles of commerce that can be produced include but are not limited by the following examples: awnings and canopies--coated fabric, tents/tarps coated fabric covers, curtains extruded soft sheet, protective cloth coated fabric, bumper fascia, instrument panel and trim skin, coated fabric for auto interior, geo textiles, appliance door gaskets, liners/gaskets/mats, hose and tubing, syringe plunger tips, light weight conveyor belt PVC replacement, modifier for rubber concentrates to reduce viscosity, single ply roofing compositions, recreation and sporting goods, grips for pens, razors, toothbrushes, handles, and the like.
  • Exemplary articles made using the compositions described herein include cookware, storage ware, toys, medical devices, sterilizable medical devices, sterilization containers, sheets, crates, containers, packaging, wire and cable jacketing, pipes, geomembranes, sporting equipment, chair mats, tubing, profiles, instrumentation sample holders and sample windows, outdoor furniture, e.g., garden furniture, playground equipment, automotive, boat and water craft components, and other such articles.
  • the impact copolymers are suitable for automotive components such as bumpers, grills, trim parts, dashboards and instrument panels, exterior door and hood components, spoiler, wind screen, hub caps, mirror housing, body panel, protective side molding, and other interior and external components associated with automobiles, trucks, boats, and other vehicles.
  • the compositions described herein can be useful for producing "soft touch" grips in products such as personal care articles such as toothbrushes, etc.; toys; small appliances; packaging; kitchenware; sport and leisure products; consumer electronics; PVC and silicone rubber replacement medical tubing; industrial hoses; and shower tubing.
  • a process to produce an impact copolymer composition includes combining a first component comprising propylene with from 10 wt% to 80 wt% of a second component, based on the total weight of the first and second components, comprising a copolymer of a linear ⁇ -olefin and a diene under melt conditions to form a homogenous melt mixture in which the first component and the second component are substantially (e.g., fully) melt miscible; cooling the melt mixture to form the impact copolymer comprising the first component as a continuous phase and the second component as a dispersed phase.
  • the process further comprises selecting the continuous phase, and/or the dispersed phase such that the continuous phase and the dispersed phase are melt miscible at the proportions utilized in the resulting impact copolymer.
  • the process includes selecting the continuous phase, e.g., a first component, and selecting the dispersed phase, e.g., a second component, such that a melt blend of the continuous phase with the dispersed phase (e.g., a melt blend of the first and second components) is a homogeneous solution, followed by cooling of the melt to produce the impact copolymer composition.
  • Copolymers of the present disclosure may be produced using processes where monomer (such as linear ⁇ -olefin), a diene, and optionally C 2 -C 10 ⁇ -olefin comonomer (such as ethylene), are contacted with a catalyst system comprising the result of the combination of an activator, optional support (such as a fluorided support), and a tetrahydroindacene compound, as described herein.
  • the catalyst compound, optional support and activator may be combined in any order, and are combined typically prior to contacting with the monomer.
  • 500 ppm or less of diene is added to the polymerization, such as 400 ppm or less, such as or 300 ppm or less. In other embodiments, at least 50 ppm of diene is added to the polymerization, or 100 ppm or more, or 150 ppm or more.
  • Linear ⁇ -olefins can be substituted or unsubstituted C 6 -C 60 LAOs, such as C 8 -C 50 LAOs, such as C 10 -C 40 LAOs, such as C 12 -C 30 LAOs, such as C 14 -C 26 LAOs, such as C 16 –C 26 LAOs, such as C 18 -C 26 LAOs, such as C 20 -C 26 LAOs.
  • LAOs can have some branching.
  • an LAO may have one or more pendant methyl or ethyl substitutions along the LAO backbone.
  • an LAO is free of branching, e.g. is entirely linear.
  • a linear ⁇ -olefin is selected from 1-octene, 1-decene, 1-undecene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene, 1-icosene, 1-henicosene, 1-docosene, 1-tricosene, 1-tetracosene, 1-pentacosene, and combination(s) thereof.
  • Dienes can be substituted or unsubstituted dienes selected from C 4 -C 60 dienes, such as C 5 -C 50 dienes, such as C 5 -C 40 dienes, such as C 5 -C 30 dienes, such as C 5 -C 20 dienes, such as C6-C15 dienes, such as C6-C10 dienes, such as C7-C9 dienes, such as a substituted or unsubstituted C 7 diene, C 8 diene, or C 9 diene.
  • a diene is a C 7 diene.
  • a diene is a substituted or unsubstituted ⁇ , ⁇ -diene (e.g., the diene is a di-vinyl monomer).
  • the dienes can be linear di-vinyl monomers.
  • a diene is selected from butadiene, pentadiene, hexadiene, heptadiene, octadiene, nonadiene, decadiene, undecadiene, dodecadiene, tridecadiene, tetradecadiene, pentadecadiene, hexadecadiene, heptadecadiene, octadecadiene, nonadecadiene, icosadiene, heneicosadiene, docosadiene, tricosadiene, tetracosadiene, pentacosadiene, hexacosadiene, heptacosadiene, octacosadiene, nonacosadiene, triacontadiene, and combination(s) thereof.
  • a diene is selected from 1,6-heptadiene, 1,7-octadiene, 1,8-nonadiene, 1,9-decadiene, 1,10-undecadiene, 1,11-dodecadiene, 1,12-tridecadiene, 1,13-tetradecadiene, and combination(s) thereof.
  • a diene is selected from cyclopentadiene, vinylnorbornene, norbornadiene, 5-ethylidene-2-norbornene, 5-vinyl-2- norbornene, divinylbenzene, dicyclopentadiene, and combination(s) thereof.
  • a diene is 5-ethylidene-2-norbornene.
  • 500 ppm or less of diene is added to the polymerization, such as 400 ppm or less, such as or 300 ppm or less. In other embodiments, at least 50 ppm of diene is added to the polymerization, or 100 ppm or more, or 150 ppm or more.
  • Polymerization processes of the present disclosure can be carried out in any suitable manner. A suspension, homogeneous, bulk, solution, slurry, or gas phase polymerization process can be used. Such processes can be run in a batch, semi-batch, or continuous mode.
  • Gas phase polymerization processes and slurry processes are preferred.
  • a homogeneous polymerization process is defined to be a process where at least 90 wt% of the product is soluble in the reaction media.
  • a bulk homogeneous process is particularly preferred.
  • a bulk process is defined to be a process where monomer concentration in all feeds to the reactor is 70 vol% or more.
  • no solvent or diluent is present or added in the reaction medium, (except for the small amounts used as the carrier for the catalyst system or other additives, or amounts typically found with the monomer; e.g., propane in propylene).
  • the process is a slurry process.
  • slurry polymerization process means a polymerization process where a supported catalyst is employed and monomers are polymerized on the supported catalyst particles. At least 95 wt% of polymer products derived from the supported catalyst are in granular form as solid particles (not dissolved in the diluent).
  • Suitable diluents/solvents for polymerization include non-coordinating, inert liquids.
  • Examples include straight and branched-chain hydrocarbons, such as isobutane, butane, pentane, isopentane, hexanes, isohexane, heptane, octane, dodecane, and mixtures thereof; cyclic and alicyclic hydrocarbons, such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof, such as can be found commercially (IsoparTM); perhalogenated hydrocarbons, such as perfluorinated C 4-10 alkanes, chlorobenzene, and aromatic and alkylsubstituted aromatic compounds, such as benzene, toluene, mesitylene, and xylene.
  • straight and branched-chain hydrocarbons such as isobutane, butane, pentane, isopentane, hexanes, isohexane,
  • Suitable solvents also include liquid olefins which may act as monomers or comonomers including ethylene, propylene, 1-butene, 1-hexene, 1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-octene, 1-decene, and mixtures thereof.
  • aliphatic hydrocarbon solvents are used as the solvent, such as isobutane, butane, pentane, isopentane, hexanes, isohexane, heptane, octane, dodecane, and mixtures thereof; cyclic and alicyclic hydrocarbons, such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof.
  • the solvent is not aromatic, such as aromatics are present in the solvent at less than 1 wt%, such as less than 0.5 wt%, such as less than 0 wt% based upon the weight of the solvents.
  • the feed concentration of the monomers and comonomers for the polymerization is 60 vol% solvent or less, such as 40 vol% or less, or such as 20 vol% or less, based on the total volume of the feedstream.
  • the polymerization is run in a bulk process.
  • Polymerizations can be run at any temperature and/or pressure suitable to obtain the desired polymers.
  • Typical temperatures and/or pressures include a temperature from about 0°C to about 300°C, such as about 20°C to about 200°C, such as about 35°C to about 150°C, such as from about 40°C to about 120°C, such as from about 45°C to about 80°C; and at a pressure from about 0.35 MPa to about 16 MPa, such as from about 0.45 MPa to about 13 MPa, such as from about 0.5 MPa to about 12 MPa.
  • the run time of the reaction is up to 300 minutes, such as from about 5 to 250 minutes, such as from about 10 to 120 minutes.
  • hydrogen is present in the polymerization reactor at a partial pressure of 0.001 to 50 psig (0.007 to 345 kPa), such as from 0.01 to 25 psig (0.07 to 172 kPa), such as 0.1 to 10 psig (0.7 to 70 kPa).
  • the activity of the catalyst is at least 800 gpolymer/gsupported catalyst/hour, such as 1,000 or more gpolymer/gsupported catalyst/hour, such as 100 or more gpolymer/gsupported catalyst/hour, such as 1,600 or more gpolymer/gsupported catalyst/hour.
  • scavenger such as tri alkyl aluminum
  • the scavenger is present at zero mol%, alternately the scavenger is present at a molar ratio of scavenger metal to transition metal of less than 100:1, such as less than 50:1, such as less than 15:1, such as less than 10:1.
  • the polymerization 1) is conducted at temperatures of 0°C to 300°C (such as 25°C to 150°C, such as 40°C to 120°C, such as 45°C to 80°C); 2) is conducted at a pressure of atmospheric pressure to 16 MPa (such as 0.35 to 14 MPa, such as from 0.45 to 12 MPa, such as from 0.5 to 6 MPa); 3) is conducted in an aliphatic hydrocarbon solvent (such as isobutane, butane, pentane, isopentane, hexanes, isohexane, heptane, octane, dodecane, and mixtures thereof; cyclic and alicyclic hydrocarbons, such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof; such as where aromatics are present in the solvent at less than 1 wt%, such as, less than
  • a “reaction zone” also referred to as a “polymerization zone” is a vessel where polymerization takes place, for example a batch reactor. When multiple reactors are used in either series or parallel configuration, each reactor is considered as a separate polymerization zone. For a multi-stage polymerization in both a batch reactor and a continuous reactor, each polymerization stage is considered as a separate polymerization zone. In at least one embodiment, the polymerization occurs in one reaction zone.
  • Gas phase polymerization [0161] Generally, in a fluidized gas bed process used for producing polymers, a gaseous stream containing one or more monomers is continuously cycled through a fluidized bed in the presence of a catalyst under reactive conditions.
  • a slurry polymerization process generally operates between 1 to about 50 atmosphere pressure range (15 psi to 735 psi, 103 kPa to 5,068 kPa) or even greater and temperatures in the range of 0 °C to about 120 °C.
  • a suspension of solid, particulate polymer is formed in a liquid polymerization diluent medium to which monomer and comonomers along with catalyst are added.
  • the suspension including diluent is intermittently or continuously removed from the reactor where the volatile components are separated from the polymer and recycled, optionally after a distillation, to the reactor.
  • the liquid diluent employed in the polymerization medium is typically an alkane having from 3 to 7 carbon atoms, such as a branched alkane.
  • the medium employed should be liquid under the conditions of polymerization and relatively inert. When a propane medium is used the process must be operated above the reaction diluent critical temperature and pressure.
  • a hexane or an isobutane medium is employed.
  • a polymerization technique herein is referred to as a particle form polymerization, or a slurry process where the temperature is kept below the temperature at which the polymer goes into solution.
  • the temperature in the particle form process may be from about 85°C to about 110°C.
  • Two example polymerization methods for the slurry process are those employing a loop reactor and those utilizing a plurality of stirred reactors in series, parallel, or combinations thereof.
  • Non-limiting examples of slurry processes include continuous loop or stirred tank processes.
  • the slurry process is carried out continuously in a loop reactor.
  • the catalyst as a slurry in isobutane or as a dry free flowing powder, is injected regularly to the reactor loop, which is itself filled with circulating slurry of growing polymer particles in a diluent of isobutane containing monomer and comonomer.
  • Hydrogen optionally, may be added as a molecular weight control. (In one embodiment 500 ppm or less of hydrogen is added, or 400 ppm or less or 300 ppm or less.
  • At least 50 ppm of hydrogen is added, or 100 ppm or more, or 150 ppm or more.
  • the reactor may be maintained at a pressure of 3,620 kPa to 4,309 kPa and at a temperature in the range of about 60°C to about 104°C depending on the desired polymer melting characteristics. Reaction heat is removed through the loop wall since much of the reactor is in the form of a double-jacketed pipe. The slurry is allowed to exit the reactor at regular intervals or continuously to a heated low pressure flash vessel, rotary dryer and a nitrogen purge column in sequence for removal of the isobutane diluent and all unreacted monomer and comonomers.
  • additives may also be used in the polymerization, as desired, such as one or more scavengers, promoters, modifiers, chain transfer agents (such as diethyl zinc), reducing agents, oxidizing agents, hydrogen, aluminum alkyls, or silanes.
  • Useful chain transfer agents are typically alkylalumoxanes, a compound represented by the formula AlR 3 , ZnR 2 (where each R is, independently, a C 1 -C 8 aliphatic radical, such as methyl, ethyl, propyl, butyl, penyl, hexyl octyl or an isomer thereof) or a combination thereof, such as diethyl zinc, methylalumoxane, trimethylaluminum, triisobutylaluminum, trioctylaluminum, or a combination thereof.
  • Polymerization Catalysts of the present disclosure for forming linear ⁇ -olefin-diene copolymers described herein can be monocyclopentadienyl group 4 transition metal compounds represented by the formula: T y Cp' m MG n X q wherein Cp' is a tetrahydroindacenyl group (such as tetrahydro-s-indacenyl or tetrahydro-as- indacenyl) which may be substituted or unsubstituted (optionally provided that when Cp' is tetrahydro-s-indecenyl: 1) the 3 and/or 4 positions are not aryl or substituted aryl, 2) the 3 position is not directly bonded to a group 15 or 16 heteroatom, 3) there are no additional rings fused to the tetrahydroindacenyl ligand, 4) T is not bonded to the 2-position, 5)
  • This invention also relates to a catalyst system comprising an activator and at least one metallocene catalyst compound, where the metallocene is a tetrahydroindacenyl group 4 transition metal compound, such as represented by the formula: T y Cp' m MG n X q wherein Cp' is a tetrahydroindacenyl group (such as tetrahydro-s-indacenyl or tetrahydro-as- indacenyl) which may be substituted or unsubstituted (optionally provided that when Cp' is tetrahydro-s-indecenyl: 1) the 3 and/or 4 positions are not aryl or substituted aryl, 2) the 3 position is not directly bonded to a group 15 or 16 heteroatom, 3) there are no additional rings fused to the tetrahydroindacenyl ligand, 4) T is not bonded to the 2-position, and/
  • each R i is a linear, branched or cyclic C 1 to C 20 hydrocarbyl group, such as independently selected from the group consisting of methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, and isomers thereof, such as t-butyl, cyclooctyl, cyclohexyl, cyclodecyl, cyclododecyl, and or adamantyl.
  • a mono-tetrahydro-s-indacenyl group 4 transition metal compound is represented by the Formula (I) or (II): ) or I) where M is a group 4 metal (such as Hf,Ti or Zr, such as Ti); J is N, O, S or P (such as N); p is 1 or 2; each R a is independently C 1 -C 10 alkyl (alternately a C 2 -C 10 alkyl); each R c is independently hydrogen or a C1-C10 alkyl; each R 2 , R 3 , R 4 , and R 7 is independently hydrogen, or a C 1 -C 50 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germylcarbyl, (preferably provided that: 1) R 3 and/or R 4 are not aryl or substituted aryl, 2) R 3 is not directly bonded to a group 15 or 16 heteroatom,
  • R a and or X is not methyl; and/or preferably, in Formula (II), when JR' is t-butylamido, adamantylamido, cyclooctylamido, cyclohexylamido or cyclododecylamido and R c are H, then R a and/or X is not methyl.
  • R a is not methyl.
  • a bridged mono-tetrahydro-as-indacenyl transition metal compound is represented by the Formula (III) or (IV): where M is group 3, 4, 5,or 6 transition metal(preferably M is a group 4 metal (such as Hf, Ti or Zr, such as Ti); B is the oxidation state of M, and is 3, 4, 5 or 6; c is B-2; J is N, O, S or P; p is 1 or 2; each R 2 , R 3 , R 6 , and R 7 , is independently hydrogen, or a C 1 -C 50 substituted or unsubstituted hydrocarbyl, halocarbyl or silylcarbyl; each R b and R c is independently C 1 -C 10 alkyl, or hydrogen; each R' is, independently, a C1-C100 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germycarbyl; T is
  • a bridged mono-tetrahydro-as-indacenyl transition metal compound is represented by the Formula (A) or (B): ) ) where M, B, c, J, p, R 2 , R 3 , R 6 , R 7 , R', T, y and X are as defined above for Formula (III) and (IV) and each R b , R c , and R d is independently C1-C10 alkyl, or hydrogen, preferably provided that both R b , both R c , or both R d are not hydrogen.
  • R d is independently selected from the group consisting of hydrogen, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and isomers thereof, such as hydrogen or methyl.
  • the present disclosure also relates to bridged monoindacenyl group 4 transition metal compounds represented by the Formula (V) or (VI):
  • M* is a group 4 transition metal (such as Hf, Zr or Ti); J is N, O, S or P (preferably J is N and p is 1); p is 1 or 2, each R 2 , R 3 , R 6 , and R 7 is independently hydrogen, or a C1-C50 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germycarbyl; each R b and each R c is independently a C1-C10 alkyl or hydrogen; each R' is, independently, a C 1 -C 100 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germylcarbyl; T is a bridging group, such as (CR 8 R 9 ) x , SiR 8 R 9 or GeR 8 R 9 where x is 1 or 2, R 8 and R 9 are independently selected from substituted or unsubstituted hydrocarbyl, halocarbyl, sily
  • M* is a group 4 metal (such as Hf, Zr or Ti); J is nitrogen; each R 2 , R 3 , R 6 , and R 7 is independently hydrogen, or a C1-C20 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germycarbyl; each R b and each R c is independently C1-C10 alkyl (such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, or an isomer thereof), or hydrogen; R' is a C1-C20 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germylcarbyl; T is (CR 8 R 9 ) x , SiR 8 R 9 or GeR 8
  • M and/or M* are a group 4 metal, such as titanium.
  • R 3 is not substituted with a group 15 or 16 heteroatom.
  • each R 2 , R 3 , R 4 , R 6 , and R 7 is independently hydrogen, or a C 1 -C 50 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germylcarbyl, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, and dodecyl or an isomer thereof.
  • each R a is independently selected from the group consisting of methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and isomers thereof, such as methyl and ethyl, such as methyl.
  • the indacene ligand does not have a methyl at the 6 position, alternately one or both R a are not methyl.
  • R b is independently selected from the group consisting of hydrogen, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and isomers thereof, such as methyl and ethyl, such as methyl.
  • R c is independently selected from the group consisting of hydrogen, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and isomers thereof, such as hydrogen or methyl.
  • R' is a C1-C100 substituted or unsubstituted hydrocarbyl, halocarbyl, or silylcarbyl, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl or an isomer thereof, such as t-butyl, neopentyl, cyclohexyl, cyclooctyl, cyclododecyl, adamantyl, or norbornyl.
  • T is a bridging group containing at least one Group 13, 14, 15, or 16 element, in particular boron or a Group 14, 15, or 16 element.
  • Preferred examples for the bridging group T include CH2, CH2CH2, SiMe2, SiPh2, SiMePh, Si(CH2)3, Si(CH2)4, O, S, NPh, PPh, NMe, PMe, NEt, NPr, NBu, PEt, PPr, Me 2 SiOSiMe 2 , and PBu.
  • T is represented by the formula ER d 2 or (ERd 2) 2 , where E is C, Si, or Ge, and each R d is, independently, hydrogen, halogen, C 1 to C 20 hydrocarbyl (such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, or dodecyl) or a C 1 to C 20 substituted hydrocarbyl, and two R d can form a cyclic structure including aromatic, partially saturated, or saturated cyclic or fused ring system.
  • C 1 to C 20 hydrocarbyl such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, or dodecyl
  • two R d can form a cyclic structure including aromatic
  • T is a bridging group comprising carbon or silica, such as dialkylsilyl, preferably T is selected from CH 2 , CH 2 CH 2 , C(CH 3 ) 2 , SiMe 2 , Me 2 Si-SiMe 2 , cyclotrimethylenesilylene (Si(CH 2 ) 3 ), cyclopentamethylenesilylene (Si(CH 2 ) 5 ) and cyclotetramethylenesilylene (Si(CH 2 ) 4 ).
  • T is CR 8 R 9 , R 8 R 9 C-CR 8 R 9 , SiR 8 R 9 or GeR 8* R 9* where R 8 and R 9 are independently selected from substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl and R 8 and R 9 may optionally be bonded together to form a ring structure, such as each R 8 and R 9 is independently methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, benzyl, phenyl, methylphenyl or an isomer thereof, such as methyl, ethyl, propyl, butyl, or hexyl.
  • R 8 or R 9 is not aryl. In at least one embodiment, R 8 is not aryl. In at least one embodiment, R 9 is not aryl. In at least one embodiment, R 8 and R 9 are not aryl. [0189] In at least one embodiment, R 8 and R 9 are independently C1-C10 alkyls, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, or an isomer thereof. [0190] In at least one embodiment, each R 2 , R 3 , R 4 , and R 7 is independently hydrogen or hydrocarbyl.
  • each R 2 , R 3 , R 6 , and R 7 is independently hydrogen or hydrocarbyl.
  • each R 2 , R 3 , R 4 , and R 7 is independently hydrogen or a C 1 -C 10 alkyl, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, or an isomer thereof.
  • each R 2 , R 3 , R 6 , and R 7 is independently hydrogen or a C1-C10 alkyl, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, or an isomer thereof.
  • R 2 is a C 1 -C 10 alkyl and R 3 , R 4 , and R 6 are hydrogen.
  • R 2 is a C1-C10 alkyl and R 3 , R 6 , and R 7 are hydrogen.
  • R 2 , R 3 , R 4 , and R 6 are hydrogen. In some embodiments, R 2 , R 3 , R 6 , and R 7 are hydrogen. [0195] In at least one embodiment, R 2 is methyl, ethyl, or an isomer of propyl, butyl, pentyl or hexyl, and R 3 , R 4 , and R 7 are hydrogen. In at least one embodiment, R 2 is methyl, ethyl, or an isomer of propyl, butyl, pentyl or hexyl, and R 3 , R 6 , and R 7 are hydrogen.
  • R 2 is methyl and R 3 , R 4 , and R 7 are hydrogen. In some embodiments, R 2 is methyl and R 3 , R 6 , and R 7 are hydrogen.
  • R 3 is hydrogen. In at least one embodiment, R 2 is hydrogen.
  • R' is C1-C100 or C1-C30 substituted or unsubstituted hydrocarbyl. [0198] In at least one embodiment, R' is C1-C30 substituted or unsubstituted alkyl (linear, branched, or cyclic), aryl, alkaryl, or heterocyclic group.
  • R' is C1-C30 linear, branched or cyclic alkyl group.
  • R' is methyl, ethyl, or any isomer of propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, or dodecyl.
  • R' is a cyclic or polycyclic hydrocarbyl.
  • R' is selected from tert-butyl, neopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, cycloundecyl, cyclododecyl, adamantyl, and norbornyl.
  • R i is selected from tert-butyl, neopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, cycloundecyl, cyclododecyl, adamantyl, and norbornyl.
  • T is selected from diphenylmethylene, dimethylmethylene, 1,2-ethylene, cyclotrimethylenesilylene, cyclotetramethylenesilylene, cyclopentamethylenesilylene, dimethylsilylene, diethylsilylene, methylethylsilylene, and dipropylsilylene.
  • each R a is independently methyl, ethyl, propyl, butyl, pentyl or hexyl.
  • each R a is independently methyl or ethyl. In at least one embodiment, each R a is methyl.
  • each R b is independently hydrogen, methyl, ethyl, propyl, butyl, pentyl or hexyl. In at least one embodiment, each R b and each R c is independently hydrogen, methyl, ethyl, propyl, butyl, pentyl or hexyl. In at least one embodiment, each R b is independently hydrogen, methyl or ethyl. In at least one embodiment, each R b is methyl. [0206] In at least one embodiment, each X is hydrocarbyl, halocarbyl, or substituted hydrocarbyl or halocarbyl.
  • X is methyl, benzyl, or halo where halo includes fluoro, chloro, bromo and iodido.
  • R 3 and/or R 4 are not aryl or substituted aryl, 2) R 3 is not directly bonded to a group 15 or 16 heteroatom, and 3) adjacent R 4 , R c , R a or R 7 do not join together to form a fused ring system, and 4) each R a is a C 1 to C 10 alkyl (such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, or an isomer thereof).
  • Useful catalysts also include compounds represented by the Formula (VII): TyCp'mMGnXq wherein Cp' is a tetrahydroindacenyl group (such as tetrahydro-s-indacenyl or tetrahydro-as- indacenyl) which may be substituted or unsubstituted, provided that when Cp' is tetrahydro-s- indecenyl: 1) the 3 and/or 4 positions are not aryl or substituted aryl, 2) the 3 position is not directly bonded to a group 15 or 16 heteroatom, 3) there are no additional rings fused to the tetrahydroindacenyl ligand, 4) T is not bonded to the 2-position, and 5) the 5, 6, or 7-position (such as the 6 position) is geminally disubstituted, such as with two C 1 -C 10 alkyl groups; M is a group 3, 4, 5, or 6 transition metal
  • M is a Group 4 transition metal (such as Hf, Ti and/or Zr, such as Ti).
  • J is N
  • R i is a linear branched or cyclic hydrocarbyl group having from one to twenty carbon atoms (such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, or an isomer thereof, including t-butyl, cyclododecyl, cyclooctyl or an isomer thereof) and z is 1 or 2, such as 1, and JR i z is cyclododecyl amido, t-butyl amido, and or 1-adamantyl amido.
  • each X may be, independently, a halide, a hydride, an alkyl group, an alkenyl group or an arylalkyl group.
  • each X is, independently, selected from the group consisting of hydrocarbyl radicals having from 1 to 20 carbon atoms, aryls, hydrides, amides, alkoxides, sulfides, phosphides, halides, dienes, amines, phosphines, ethers, and a combination thereof, (two X’s may form a part of a fused ring or a ring system), such as each X is independently selected from halides, aryls and C 1 to C 5 alkyl groups, such as each X is a phenyl, methyl, ethyl, propyl, butyl, pent
  • the Cp' group may be substituted with a combination of substituent groups R.
  • substituent groups R include one or more from the group selected from hydrogen, or linear, branched alkyl radicals, or alkenyl radicals, alkynyl radicals, cycloalkyl radicals or aryl radicals, acyl radicals, alkoxy radicals, aryloxy radicals, alkylthio radicals, dialkylamino radicals, alkoxycarbonyl radicals, aryloxycarbonyl radicals, carbamoyl radicals, alkyl- or dialkyl- carbamoyl radicals, acyloxy radicals, acylamino radicals, aroylamino radicals, straight, branched or cyclic, alkylene radicals, or combination thereof.
  • substituent groups R have up to 50 non-hydrogen atoms, such as from 1 to 30 carbon, that can also be substituted with halogens or heteroatoms or the like, provided that when Cp' is tetrahydro-s- indecenyl: 1) the 3 and/or 4 position is not aryl or substituted aryl, 2) the 3-position is not substituted with a group 15 or 16 heteroatom, 3) there are no additional rings fused to the tetrahydroindacenyl ligand, 4) T is not bonded to the 2-position, and 5) the 5, 6, or 7-position (such as the 6 position) is geminally disubstituted, such as with two C 1 -C 10 alkyl groups.
  • Non- limiting examples of alkyl substituents R include methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, benzyl or phenyl groups and the like, including all their isomers, for example, tertiary butyl, isopropyl and the like.
  • hydrocarbyl radicals include fluoromethyl, fluoroethyl, difluoroethyl, iodopropyl, bromohexyl chlorobenzyl and hydrocarbyl substituted organometalloid radicals including trimethylsilyl, trimethylgermyl, methyldiethylsilyl and the like; and halocarbyl-substituted organometalloid radicals including tris(trifluoromethyl)-silyl, methylbis(difluoromethyl)silyl, bromomethyldimethylgermyl and the like; and disubstituted boron radicals including dimethylboron for example; and disubstituted pnictogen radicals including dimethylamine, dimethylphosphine, diphenylamine, methylphenylphosphine, chalcogen radicals including methoxy, ethoxy, propoxy, phenoxy, methylsulfide and ethylsulfide.
  • Non-hydrogen substituents R include the atoms carbon, silicon, boron, aluminum, nitrogen, phosphorus, oxygen, tin, sulfur, germanium and the like, including olefins such as, but not limited to, olefinically unsaturated substituents including vinyl-terminated ligands, for example but-3-enyl, prop-2-enyl, hex-5-enyl and the like.
  • the Cp' group, the substituent(s) R are, independently, hydrocarbyl groups, heteroatoms, or heteroatom containing groups, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl or an isomer thereof, N, O, S, P, or a C1 to C20 hydrocarbyl substituted with an N, O, S and or P heteroatom or heteroatom containing group (typically having up to 12 atoms, including the N, O, S and P heteroatoms), provided that when Cp' is tetrahydro-s- indecenyl, the 3 and/or 4 position are not aryl or substituted aryl, the 3 position is not substituted with a group 15 or 16 heteroatom, and there are no additional rings fused to the
  • the Cp' group is tetrahydro-as- indecenyl which may be substituted.
  • y is 1 and T is a bridging group containing at least one Group 13, 14, 15, or 16 element, in particular boron or a Group 14, 15 or 16 element.
  • Examples for the bridging group T include CH 2 , CH 2 CH 2 , SiMe 2 , SiPh 2 , SiMePh, Si(CH2)3, Si(CH2)4, O, S, NPh, PPh, NMe, PMe, NEt, NPr, NBu, PEt, PPr, Me2SiOSiMe2, and PBu.
  • R* is not aryl.
  • R* is not aryl or substituted aryl.
  • T is represented by the formula ER d d 2 or (ER 2 )2, where E is C, Si, or Ge, and each R d is, independently, hydrogen, halogen, C 1 to C 20 hydrocarbyl (such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, or dodecyl) or a C 1 to C 20 substituted hydrocarbyl, and two R d can form a cyclic structure including aromatic, partially saturated, or saturated cyclic or fused ring system.
  • C 1 to C 20 hydrocarbyl such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, or dodecyl
  • two R d can form a cyclic structure including
  • T is a bridging group comprising carbon or silica, such as dialkylsilyl, such as T is selected from CH 2 , CH 2 CH 2 , C(CH 3 ) 2 , SiMe 2 , cyclotrimethylenesilylene (Si(CH 2 ) 3 ), cyclopentamethylenesilylene (Si(CH 2 ) 5 ) and cyclotetramethylenesilylene (Si(CH 2 ) 4 ).
  • R d is not aryl or substituted aryl.
  • metallocenes for use in a catalyst system include: dimethylsilylene(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1- yl)(cyclododecylamido)M(R) 2 (such as TiCl 2 or TiMe 2 ), dimethylsilylene(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R) 2 (such as TiCl 2 or TiMe2), dimethylsilylene(6,6-dimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(cyclododecylamido)M(R) 2 (such as TiCl 2 or TiMe2), dimethylsilylene (6,6-dimethyl-1,5,6,7-tetrahydro-s-indacen-1- yl)(cyclododecylamid
  • a catalyst system includes ⁇ -(CH 3 ) 2 Si( ⁇ 5 -2,6,6- trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)( tertbutylamido)M(R) 2 ; where M is selected from a group consisting of Ti, Zr, and Hf and R is selected from halogen or C 1 to C 5 alkyl, such as, R is a methyl group. In an embodiment, M is Ti and R is Cl, Br or Me. [0222] In alternate embodiments, two or more different transition metal compounds may be used herein. For purposes of the present disclosure one transition metal compound is considered different from another if they differ by at least one atom.
  • Me2Si(2,7,7-Me3-3,6,7,8-tetrahydro-as-indacen-3-yl)(cyclohexylamido)TiCl 2 is different from Me2Si(2,7,7-Me3-3,6,7,8-tetrahydro-as-indacen-3-yl)(n-butylamido)TiCl 2 which is different from Me2Si(2,7,7-Me3-3,6,7,8-tetrahydro-as-indacen-3-yl)(n-butylamido)HfCl 2 .
  • one mono-tetrahydroindacenyl compound as described herein is used in the catalyst system.
  • indacenyl catalyst compounds that are useful herein and methods to prepare them, please US 2015-0119539; US 2017-0320976, US 2016-0244535, US 2018-0094088; US 2019-0292282; US 2017-0342175; US 2019-0161560; US 2019-0119418; and US 9,458,254.
  • Activators [0225]
  • cocatalyst and activator are used herein interchangeably and are defined to be any compound which can activate any one of the catalyst compounds described above by converting the neutral catalyst compound to a catalytically active catalyst compound cation.
  • Non-limiting activators include alumoxanes, aluminum alkyls, ionizing activators, which may be neutral or ionic, and conventional-type cocatalysts.
  • Activators typically include alumoxane compounds, modified alumoxane compounds, and ionizing anion precursor compounds that abstract a reactive, ⁇ -bound, metal ligand making the metal complex cationic and providing a charge-balancing non-coordinating or weakly coordinating anion.
  • Alumoxane Activators [0226] Alumoxane activators are utilized as activators in the catalyst systems described herein. Alumoxanes are generally oligomeric compounds containing -Al(R 1 )-O- sub-units, where R 1 is an alkyl group.
  • alumoxanes examples include methylalumoxane (MAO), modified methylalumoxane (MMAO), ethylalumoxane and isobutylalumoxane.
  • Alkylalumoxanes and modified alkylalumoxanes are suitable as catalyst activators, particularly when the abstractable ligand is an alkyl, halide, alkoxide or amide. Mixtures of different alumoxanes and modified alumoxanes may also be used. It may be preferable to use a visually clear methylalumoxane.
  • a cloudy or gelled alumoxane can be filtered to produce a clear solution or clear alumoxane can be decanted from the cloudy solution.
  • a useful alumoxane is a modified methyl alumoxane (MMAO) cocatalyst type 3A (commercially available from Akzo Chemicals, Inc. under the trade name Modified Methylalumoxane type 3A, covered under patent number US Patent No.5,041,584).
  • MMAO modified methyl alumoxane
  • some embodiments select the maximum amount of activator typically at up to a 5,000-fold molar excess Al/M over the catalyst compound (per metal catalytic site).
  • Non-coordinating anion activators may also be used herein.
  • the term "non- coordinating anion” means an anion which either does not coordinate to a cation or which is only weakly coordinated to a cation thereby remaining sufficiently labile to be displaced by a neutral Lewis base.
  • “Compatible" non-coordinating anions are those which are not degraded to neutrality when the initially formed complex decomposes.
  • Non-coordinating anions useful in accordance with the present disclosure are those that are compatible, stabilize the transition metal cation in the sense of balancing its ionic charge at +1, and yet retain sufficient lability to permit displacement during polymerization.
  • an ionizing or stoichiometric activator such as tri (n-butyl) ammonium tetrakis (pentafluorophenyl) borate, a tris perfluorophenyl boron metalloid precursor or a tris perfluoronaphthyl boron metalloid precursor, polyhalogenated heteroborane anions (WO 1998/043983), boric acid (US Patent No. 5,942,459), in combination with the alumoxane or modified alumoxane activators.
  • neutral or ionic such as tri (n-butyl) ammonium tetrakis (pentafluorophenyl) borate, a tris perfluorophenyl boron metalloid precursor or a tris perfluoronaphthyl boron metalloid precursor, polyhalogenated heteroborane anions (WO 1998/043983), boric acid (US Patent No. 5,942,459), in combination
  • the catalyst systems of the present disclosure can include at least one non- coordinating anion (NCA) activator.
  • the catalyst systems may include an NCAs which either do not coordinate to a cation or which only weakly coordinate to a cation thereby remaining sufficiently labile to be displaced during polymerization.
  • NCA non- coordinating anion
  • the terms “cocatalyst” and “activator” are used herein interchangeably and are defined to be any compound which can activate any one of the catalyst compounds described above by converting the neutral catalyst compound to a catalytically active catalyst compound cation.
  • boron containing NCA activators represented by the formula below can be used: Z d + ( A d- ) where: Z is (L-H) or a reducible Lewis acid; L is a neutral Lewis base; H is hydrogen; (L-H) is a Bronsted acid; A d- is a boron containing non-coordinating anion having the charge d-; d is 1, 2, or 3.
  • the cation component, Zd + may include Bronsted acids such as protons or protonated Lewis bases or reducible Lewis acids capable of protonating or abstracting a moiety, such as an alkyl or aryl, from the bulky ligand metallocene containing transition metal catalyst precursor, resulting in a cationic transition metal species.
  • the activating cation Z d + may also be a moiety such as silver, tropylium, carboniums, ferroceniums and mixtures, such as carboniums and ferroceniums. Such as Z d + is triphenyl carbonium.
  • Reducible Lewis acids can be any triaryl carbonium (where the aryl can be substituted or unsubstituted, such as those represented by the formula: (Ar 3 C + ), where Ar is aryl or aryl substituted with a heteroatom, a C 1 to C 40 hydrocarbyl, or a substituted C 1 to C40 hydrocarbyl), such as the reducible Lewis acids in formula (14) above as “Z” include those represented by the formula: (Ph 3 C), where Ph is a substituted or unsubstituted phenyl, such as substituted with C 1 to C 40 hydrocarbyls or substituted a C 1 to C 40 hydrocarbyls, such as C 1 to C20 alkyls or aromatics or substituted C1 to C20 alkyls or aromatics, such as Z is a triphenylcarbonium.
  • the aryl can be substituted or unsubstituted, such as those represented by the formula: (Ar 3 C + ), where Ar is aryl
  • Z d + is the activating cation (L-H) d + , it is preferably a Bronsted acid, capable of donating a proton to the transition metal catalytic precursor resulting in a transition metal cation, including ammoniums, oxoniums, phosphoniums, silyliums, and mixtures thereof, such as ammoniums of methylamine, aniline, dimethylamine, diethylamine, N-methylaniline, diphenylamine, trimethylamine, triethylamine, N,N-dimethylaniline, methyldiphenylamine, pyridine, p-bromo N,N-dimethylaniline, p-nitro-N,N-dimethylaniline, phosphoniums from triethylphosphine, triphenylphosphine, and diphenylphosphine, oxomiuns from ethers such as dimethyl ether diethyl ether,
  • the activating cation Z d + may also be a moiety such as [R 1' , R 2' ,R 3' EH] d+ , where E is N or P, d is 12 or 3, and R 1' , R 2' , and R 3' are independently a C1 to C50 hydrocarbyl group optionally substituted with one or more alkoxy groups, silyl groups, a halogen atoms, or halogen containing groups, wherein together R 1' , R 2' , and R 3' comprise 15 or more carbon atoms (such as 18 or more carbon atoms, such as 20 or more carbon atoms, such as 22 or more carbon atoms, such as 25 or more carbon atoms, such as 30 or more carbon atoms, such as 35 or more carbon atoms, such as 38 or more carbon atoms, such as 40 or more carbon atoms, such as 15 to 100 carbon atoms, such as 25 to 75 carbon atoms). [0237] Useful
  • Useful cation components, Z d + include those represented by the formulas: [0239]
  • each Q is a fluorinated hydrocarbyl group having 1 to 20 carbon atoms, such as each Q is a fluorinated aryl group, and such as each Q is a pentafluoryl aryl group.
  • suitable A d- also include diboron compounds as disclosed in US Patent No.5,447,895, which is fully incorporated herein by reference.
  • Illustrative, but not limiting, examples of boron compounds which may be used as an activating cocatalyst are the compounds described as (and particularly those specifically listed as) activators in US 8,658,556, which is incorporated by reference herein.
  • the ionic stoichiometric activator Z d + (A d- ) is one or more of N,N- dimethylanilinium tetra(perfluorophenyl)borate, N,N-dimethylanilinium tetrakis(perfluoronaphthyl)borate, N,N-dimethylanilinium tetrakis(perfluorobiphenyl)borate, N,N-dimethylanilinium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, triphenylcarbenium tetrakis(perfluoronaphthyl)borate, triphenylcarbenium tetrakis(perfluorobiphenyl)borate, triphenylcarbenium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, or triphenylcarbenium tetra(perfluorophenyl)
  • Bulky activator refers to anionic activators represented by the formula: or R R where: each R 1 is, indep endently, a halide, such as a fluoride; Ar is substituted or unsubstituted aryl group (such as a substituted or unsubstituted phenyl), such as substituted with C 1 to C 40 hydrocarbyls, such as C 1 to C 20 alkyls or aromatics; each R 2 is, independently, a halide, a C 6 to C 20 substituted aromatic hydrocarbyl group or a siloxy group of the formula –O-Si-R a , where R a is a C 1 to C 20 hydrocarbyl or hydrocarbylsilyl group (such as R 2 is a fluoride or a perfluorinated phenyl group); each R 3 is a halide, C 6 to C 20 substituted aromatic
  • (Ar 3 C) d + is (Ph 3 C) d + , where Ph is a substituted or unsubstituted phenyl, such as substituted with C 1 to C 40 hydrocarbyls or substituted C 1 to C 40 hydrocarbyls, such as C 1 to C 20 alkyls or aromatics or substituted C 1 to C 20 alkyls or aromatics.
  • Ph is a substituted or unsubstituted phenyl, such as substituted with C 1 to C 40 hydrocarbyls or substituted C 1 to C 40 hydrocarbyls, such as C 1 to C 20 alkyls or aromatics or substituted C 1 to C 20 alkyls or aromatics.
  • “Molecular volume” is used herein as an approximation of spatial steric bulk of an activator molecule in solution. Comparison of substituents with differing molecular volumes allows the substituent with the smaller molecular volume to be considered “less bulky” in comparison to the substituent with the larger molecular volume.
  • a substituent with a larger molecular volume may be considered more bulky than a substituent with a smaller molecular volume.
  • Molecular volume may be calculated as reported in “A Simple ‘Back of the Envelope’ Method for Estimating the Densities and Molecular Volumes of Liquids and Solids,” Journal of Chemical Education, v.71(11), November 1994, pp. 962-964.
  • V s is the sum of the relative volumes of the constituent atoms, and is calculated from the molecular formula of the substituent using the following table of relative volumes.
  • Activators can include N,N-dimethylanilinium tetrakis(perfluoronaphthyl)borate, N,N-dimethylanilinium tetrakis(perfluorobiphenyl)borate, N,N-dimethylanilinium tetrakis(perfluorophenyl)borate, N,N-dimethylanilinium tetrakis(3,5- bis(trifluoromethyl)phenyl)borate, triphenylcarbenium tetrakis(perfluoronaphthyl)borate, triphenylcarbenium tetrakis(perfluorobiphenyl)borate, triphenylcarbenium tetrakis(3,5- bis(trifluoromethyl)phenyl)borate, triphenylcarbenium tetrakis(perfluorophenyl)borate, [Ph 3 C + ][B(C 6 F
  • the activator comprises a triaryl carbonium (such as triphenylcarbenium tetraphenylborate, triphenylcarbenium tetrakis(pentafluorophenyl)borate, triphenylcarbenium tetrakis-(2,3,4,6-tetrafluorophenyl)borate, triphenylcarbenium tetrakis(perfluoronaphthyl)borate, triphenylcarbenium tetrakis(perfluorobiphenyl)borate, triphenylcarbenium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate).
  • a triaryl carbonium such as triphenylcarbenium tetraphenylborate, triphenylcarbenium tetrakis(pentafluorophenyl)borate, triphenylcarbenium tetrakis-(2,3,4,6-tetra
  • the activator comprises one or more of trialkylammonium tetrakis(pentafluorophenyl)borate, N,N-dialkylanilinium tetrakis(pentafluorophenyl)borate, N,N-dimethyl-(2,4,6-trimethylanilinium) tetrakis(pentafluorophenyl)borate, trialkylammonium tetrakis-(2,3,4,6-tetrafluorophenyl) borate, N,N-dialkylanilinium tetrakis- (2,3,4,6-tetrafluorophenyl)borate, trialkylammonium tetrakis(perfluoronaphthyl)borate, N,N-dialkylanilinium tetrakis(perfluoronaphthyl)borate, trialkylammonium tetrakis(perfluorobiphen
  • Activator compounds that are particularly useful in this invention include one or more of: N,N-di(hydrogenated tallow)methylammonium [tetrakis(perfluorophenyl) borate], N-methyl-4-nonadecyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-hexadecyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-tetradecyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-dodecyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-dodecyl-N-octadecylanilinium [t
  • the typical NCA activator-to-catalyst ratio e.g., all NCA activators-to-catalyst ratio is about a 1:1 molar ratio. Alternate ranges include from 0.1:1 to 100:1, alternately from 0.5:1 to 200:1, alternately from 1:1 to 500:1 alternately from 1:1 to 1000:1. A particularly useful range is from 0.5:1 to 10:1, such as 1:1 to 5:1.
  • Activators useful herein also include those described in US 7,247,687 at column 169, line 50 to column 174, line 43, particularly column 172, line 24 to column 173, line 53.
  • the catalyst compounds can be combined with combinations of alumoxanes and NCA's (see for example, US 5,153,157, US 5,453,410, EP 0573120 B1, WO 1994/007928, and WO 1995/014044 which discuss the use of an alumoxane in combination with an ionizing activator).
  • the catalyst systems used herein preferably contain 0 ppm (alternately less than 1 ppm) of residual aromatic hydrocarbon.
  • the catalyst systems used herein contain 0 ppm (alternately less than 1 ppm) of residual toluene.
  • Optional Scavengers or Co-Activators [0258] In addition to the activator compounds, scavengers, chain transfer agents or co- activators may be used.
  • Aluminum alkyl or organoaluminum compounds which may be utilized as scavengers or co-activators include, for example, trimethylaluminum, triethylaluminum, triisobutylaluminum, tri-n-hexylaluminum, tri-n-octylaluminum, and diethyl zinc.
  • Useful chain transfer agents that may also be used herein are typically a compound represented by the formula AlR3, ZnR2 (where each R is, independently, a C1-C8 aliphatic radical, such as methyl, ethyl, propyl, butyl, penyl, hexyl octyl or an isomer thereof) or a combination thereof, such as diethyl zinc, trimethylaluminum, triisobutylaluminum, trioctylaluminum, or a combination thereof.
  • the complexes described herein may be supported (with or without an activator) by any method effective to support other coordination catalyst systems, effective meaning that the catalyst so prepared can be used for oligomerizing or polymerizing olefin in a heterogeneous process.
  • the catalyst precursor, activator, co-activator if needed, suitable solvent, and support may be added in any order or simultaneously.
  • the complex and activator may be combined in solvent to form a solution. Then the support is added, and the mixture is stirred for 1 minute to 10 hours.
  • the total solution volume may be greater than the pore volume of the support, but some embodiments limit the total solution volume below that needed to form a gel or slurry (about 90% to 400%, such as about 100-200% of the pore volume).
  • the residual solvent is removed under vacuum, typically at ambient temperature and over 10-16 hours. But greater or lesser times and temperatures are possible.
  • the complex may also be supported absent the activator; in that case, the activator (and co-activator if needed) is added to a polymerization process's liquid phase. Additionally, two or more different complexes may be placed on the same support. Likewise, two or more activators or an activator and co-activator may be placed on the same support.
  • Suitable solid particle supports are typically comprised of polymeric or refractory oxide materials, each being porous.
  • any support material that has an average particle size greater than 10 ⁇ m is suitable for use.
  • a porous support material such as for example, talc, inorganic oxides, inorganic chlorides, for example magnesium chloride and resinous support materials such as polystyrene polyolefin or polymeric compounds or any other organic support material and the like.
  • Some embodiments select inorganic oxide materials as the support material including Group-2, -3, -4, -5, -13, or -14 metal or metalloid oxides.
  • Some embodiments select the catalyst support materials to include silica, alumina, silica-alumina, and their mixtures.
  • inorganic oxides may serve either alone or in combination with the silica, alumina, or silica-alumina. These are magnesia, titania, zirconia, and the like. Lewis acidic materials such as montmorillonite and similar clays may also serve as a support. In this case, the support can optionally double as the activator component, however, an additional activator may also be used.
  • the support material may be pretreated by any number of methods. For example, inorganic oxides may be calcined, chemically treated with dehydroxylating agents such as aluminum alkyls and the like, or both.
  • polymeric carriers will also be suitable in accordance with the present disclosure, see for example the descriptions in WO 1995/015815 and US 5,427,991.
  • the methods disclosed may be used with the catalyst complexes, activators or catalyst systems of the present disclosure to adsorb or absorb them on the polymeric supports, particularly if made up of porous particles, or may be chemically bound through functional groups bound to or in the polymer chains.
  • Useful supports typically have a surface area of 10-700 m 2 /g, a pore volume of 0.1-4.0 cc/g and an average particle size of 10-500 ⁇ m.
  • Some embodiments select a surface area of 50-500 m 2 /g, a pore volume of 0.5-3.5 cc/g, or an average particle size of 20-200 ⁇ m. Other embodiments select a surface area of 100-400 m 2 /g, a pore volume of 0.8-3.0 cc/g, and an average particle size of 30-100 ⁇ m.
  • Useful supports typically have a pore size of 10-1,000 Angstroms, alternatively 50-500 Angstroms, or 75-350 Angstroms.
  • catalyst complexes described herein are generally deposited on the support at a loading level of 10-100 micromoles of complex per gram of solid support; alternately 20-80 micromoles of complex per gram of solid support; or 40-60 micromoles of complex per gram of support. But greater or lesser values may be used provided that the total amount of solid complex does not exceed the support's pore volume.
  • catalyst complexes and catalyst systems described herein may be present on a fluorided support, e.g., a support, desirably particulate and porous, which has been treated with at least one inorganic fluorine containing compound.
  • the fluorided support composition can be a silicon dioxide support wherein a portion of the silica hydroxyl groups has been replaced with fluorine or fluorine containing compounds.
  • a useful support herein is a silica support treated with ammonium hexafluorosilicate and/or ammonium tetrafluoroborate fluorine compounds.
  • the fluorine concentration present on the support is in the range of 0.1 to 25 wt%, alternately 0.19 to 19 wt%, alternately from 0.6 to 3.5 wt%, based upon the weight of the support.
  • the catalyst system comprises fluorided silica, alkylalumoxane activator, and the bridged monocyclopentadienyl group 4 transition metal compound, where the fluorided support has preferably not been calcined at a temperature of 400°C or more.
  • the catalyst system the reaction product of fluorides silica support, alkylalumoxane activator and ⁇ -(CH3)2Si( ⁇ 5 -2,6,6-trimethyl-1,5,6,7-tetrahydro-s- indacen-1-yl)(tertbutylamido)M(R) 2 ; where M is selected from a group consisting of Ti, Zr, and Hf and R is selected from halogen or C1 to C5 alkyl, where the fluorided silica support has preferably not been calcined at a temperature of 400°C or more.
  • the catalyst compound may be present on a support at 1 to 100 ⁇ mol/g supported catalyst, such as 20-60 ⁇ mol/g supported catalyst.
  • the present disclosure also relates to metallocene catalyst compositions comprising the reaction product of at least three components: (1) one or more bridged metallocenes having one tetrahydroindacenyl group; (2) one or more alkylalumoxane activators; and (3) one or more fluorided support compositions, where the fluorided support composition has not been calcined at 400°C or more, such as the fluorided support composition has been calcined at a temperature of 100°C to 395°C, alternately 125°C to 350°C, alternately 150°C to 300°C.
  • the fluorided supports described herein are prepared by combining a solution of polar solvent (such as water) and fluorinating agent (such as SiF4 or (NH4)2SiF6) with a slurry of support (such as a toluene slurry of silica), then drying until it is free flowing, and optionally, calcining (typically at temperatures over 100°C for at least 1 hour).
  • polar solvent such as water
  • fluorinating agent such as SiF4 or (NH4)2SiF6
  • a slurry of support such as a toluene slurry of silica
  • a copolymer comprising: about 50 wt% to about 99.9 wt% C 6 -C 60 linear ⁇ -olefin units, based on the weight of the copolymer; diene units; and C 2 -C 10 ⁇ -olefin comonomer units different than the C 6 -C 60 linear ⁇ -olefin units.
  • Clause 2. The copolymer of Clause 1, wherein the copolymer comprises ethylene units.
  • Clause 3 The copolymer of Clauses 1 or 2, wherein the copolymer has about 90 wt% to about 99 wt% C 6 -C 60 linear ⁇ -olefin units, based on the weight of the copolymer.
  • Clause 5. The copolymer of any of Clauses 1 to 4, wherein the C 6 -C 60 linear ⁇ -olefin comprises 1-decene or 1-octadecene.
  • Clause 6. The copolymer of any of Clauses 1 to 5, wherein the copolymer comprises of about 1 wt% to about 10 wt% diene units, based on the weight of the copolymer.
  • Clause 8. The copolymer of any of Clauses 1 to 7, wherein the diene comprises C 7 -C 9 dienes.
  • Clause 9. The copolymer of any of Clauses 1 to 8, wherein the diene is selected from the group consisting of vinylnorbornene, norbornadiene, 5-ethylidene-2-norbornene, 5-vinyl-2- norbornene, divinylbenzene, dicyclopentadiene, and combination(s) thereof.
  • Clause 11. The copolymer of any of Clauses 1 to 10, wherein the diene is 5-ethylidene- 2-norbornene.
  • Clause 12. The copolymer of any of Clauses 1 to 11, wherein the diene is an ⁇ , ⁇ -diene.
  • Clause 13. The copolymer of any of Clauses 1 to 12, wherein the copolymer comprises about 1.5 wt% to about 2.5 wt% ethylene units, based on the weight of the copolymer.
  • Clause 15. The copolymer of any of Clauses 1 to 14, wherein the copolymer has an Mw value of about 100,000 g/mol to about 500,000 g/mol.
  • Clause 16. The copolymer of any of Clauses 1 to 15, wherein the copolymer has an Mw value of about 200,000 g/mol to about 300,000 g/mol.
  • Clause 19 The copolymer of any of Clauses 1 to 18, wherein the copolymer has an Mw/Mn value from 2 to 3.
  • Clause 20 The copolymer of any of Clauses 1 to 19, wherein the copolymer has a glass transition temperature (Tg) of about -50°C to about -70°C.
  • Tg glass transition temperature
  • Clause 21 The copolymer of any of Clauses 1 to 20, wherein the copolymer has a crystallization temperature (Tc) of about 60°C to about 80°C.
  • a crosslinked copolymer having one or more of (or each of) the following properties: a tensile set @200% deformation of about 0.1% to about 50% or less; a tensile strength at 23°C of about 50 kPa to about 1,000 kPa; an E dis of about 1 kJ/m 3 to about 10 kJ/m 3 ; an elongation at break of about 10% to about 1,000%; a Young’s modulus (at 40°C) of about 50 kPa to about 1,000 kPa; a glass transition temperature (Tg) of about –100°C to about 0°C; a melting temperature (Tm) of about 50°C to about 150°C; and/or a temperature of crystallization (Tc) of about 10°C to about 150°C.
  • Tg glass transition temperature
  • Tm melting temperature
  • Tc temperature of crystallization
  • Clause 23 The crosslinked copolymer of any of Clauses 1 to 22, wherein the crosslinked copolymer has a tensile set of about 3% to about 7%.
  • Clause 24 The crosslinked copolymer of any of Clauses 1 to 23, wherein the crosslinked copolymer has a tensile strength of about 400 kPa to about 650 kPa.
  • Clause 25 The crosslinked copolymer of any of Clauses 1 to 24, wherein the crosslinked copolymer has an elongation at break of about 400% to about 500%.
  • Clause 26 The crosslinked copolymer of any of Clauses 1 to 25, wherein the crosslinked copolymer has an elongation at break of about 150% to about 250%.
  • Clause 27 The crosslinked copolymer of any of Clauses 1 to 26, wherein the crosslinked copolymer has a Young’s modulus (at 40°C) of about 500 kPa to about 600 kPa.
  • Clause 28 The crosslinked copolymer of any of Clauses 1 to 27, wherein the crosslinked copolymer has a glass transition temperature (Tg) of about –70°C to about –60°C.
  • Clause 29 The crosslinked copolymer of any of Clauses 1 to 28, wherein the crosslinked copolymer has a melting temperature (Tm) of about 90°C to about 110°C.
  • Tm melting temperature
  • Tm melting temperature
  • Clause 31 The crosslinked copolymer of any of Clauses 1 to 30, wherein the crosslinked copolymer has a temperature of crystallization (Tc) of about 60°C to about 80°C.
  • Clause 32 The crosslinked copolymer of any of Clauses 1 to 31, wherein the crosslinked copolymer has a temperature of crystallization (Tc) of about 10°C to about 35°C.
  • An impact copolymer comprising: from 10 wt% to 80 wt% of the copolymer of any of Clauses 1 to 32, based on the weight of the impact copolymer; and a polypropylene.
  • Clause 34 The impact copolymer of Clause 33, wherein the impact copolymer comprises: a continuous phase comprising the polypropylene; and a dispersed phase comprising the copolymer.
  • Clause 35 The impact copolymer of Clauses 33 or 34, wherein the dispersed phase comprises less than 5 wt% polypropylene, based on the weight of the dispersed phase.
  • Clause 37. The impact copolymer of any of Clauses 33 to 36, wherein the impact copolymer is free of oil.
  • Clause 38. The impact copolymer of any of Clauses 33 to 37, wherein the impact copolymer has less than 150 phr oil.
  • Clause 39. The impact copolymer of any of Clauses 33 to 38, wherein the impact copolymer has less than 25 phr oil.
  • Clause 40. The impact copolymer of any of Clauses 33 to 39, wherein the impact copolymer has 0 phr oil.
  • Clause 41 An article comprising the impact copolymer of any of Clauses 33 to 40.
  • Clause 42 A process to produce an impact copolymer comprising: combining a first component comprising polypropylene with from 10 wt% to 80 wt% of a second component comprising the copolymer of Clause 1 or Clause 22, under melt conditions, to form a homogenous melt mixture; and cooling the melt mixture to form the impact copolymer comprising the first component as a continuous phase and the second component as a dispersed phase, Clause 43.
  • a process to produce the copolymer of any of Clauses 1 to 32 comprising: introducing a Ce-Ceo linear ⁇ -olefin, a diene, and optionally C 2 -C 10 a-olefin comonomer (different than the Ce-Ceo linear a-olefin) to a catalyst system comprising an activator and a tetrahydroindacenyl catalyst compound.
  • Clause 44 The process of Clause 43, wherein the process occurs at a temperature of about 0°C to about 300°C, at a pressure in the range of about 0.35 MPa to about 16 MPa, and at a time up to 300 minutes.
  • Clause 45 The process of Clauses 43 or 44, wherein: the linear a-olefin comprises 1-decene and/or 1-octadecene, and the diene comprises 5-ethylidene-2-norbomene.
  • Clause 46 The process of any of Clauses 43 to 45, wherein the tetrahydroindacenyl catalyst compound IS ⁇ -(CH 3 ) 2 Si( ⁇ 5 -2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-l- yl)(tertbutylamido)M(R) 2 ; wherein M is selected from the group consisting of Ti, Zr, and Hf, and R is selected from the group consisting of halogen and C 1 to C 5 alkyl.
  • Clause 47 The process of of any of Clauses 43 to 46, wherein the activator is represented by the formula:
  • R 1' , R 2' , and R 3' are independently a C 1 to C 50 hydrocarbyl group optionally substituted with one or more alkoxy groups, silyl groups, a halogen atoms, or halogen containing groups, wherein R 1' , R 2' , and R 3' together comprise 15 or more carbon atoms; ⁇ 3 is an element selected from group 13 of the Periodic Table of the Elements; and each 6 is independently a hydride, bridged or unbridged dialkylamido, halide, alkoxide, aryloxide, hydrocarbyl, substituted hydrocarbyl, halocarbyl, substituted halocarbyl, or halosubstituted-hydrocarbyl radical.
  • Clause 48 The process of any of Clauses 43 to 46, wherein the activator is represented by the formula: Z d + ( A d- ) wherein A d- is a non-coordinating anion having the charge d-; and d is 1, 2 or 3 and (Z) d + is represented by one or more of: 10 11 12 31 32 33 [0275]
  • GPC The molecular weight distribution, molecular weight moments (Mw, Mn, Mw/Mn) and long chain branching indices were determined by using a GPC hyphenated with multiple detectors including DRI, Viscometer and Light Scattering detector.
  • the conventional molecular weight was determined by combining universal calibration relationship with the column calibration which was performed with a series of monodispersed polystyrene (PS) standards ranging from 300 g/mole to 12,000,000 g/mole.
  • PS monodispersed polystyrene
  • M molecular weight “M” at each elution volume was calculated with following equation: log(K /K ) a ⁇ PS ⁇ P ⁇ 1 log M S log M a ⁇ 1 a ⁇ 1 PS where the variables with subscript "PS" stand for polystyrene while those without a subscript are for the test samples.
  • ENB 5-ethylidene-2-norbornene.
  • Alpha-olefin ethylene diene polymer (AOEDM) synthesis [0277] Alpha-olefins (AO) ranging from 1-hexene (C 6 H 14 ) to 1-hexacontane (C 60 H 122 ) are copolymerized with ethylene and a diene by organo ⁇ metallic coordinative insertion polymerization using catalyst 1 (the structure shown below).
  • Table 1 shows synthesis conditions of DE, DEDM, ODE, and ODEM examples prepared via the procedure described above, as well as the Mw, PDI and composition, measured by GPC and NMR, respectively. C 13 NMR and H 1 NMR results confirm the ability of Catalyst 1 to incorporate large amounts of AO and ENB in the compolymer, when the reaction is performed in the presence of ethylene.
  • the simplified structure of the random terpolymers is shown below. Table 1.
  • AOEDM synthesis conditions. s l Curing behavior of the AOEDM terpolymers.
  • FIGS.1 to 3 demonstrate the curing behavior typical of diene-containing rubbers. Cure reversion is observed in the sulfur formulations, which is typical for this type of curing system. UV-curing is very slow, compared to the thermal curing (FIG. 3), which allows good crosslink density control.
  • FIG. 1 dicumyl peroxide (1 phr), sulfur (2phr), and photoinitiator 1-hydroxycyclohexyl phenyl ketone
  • a small sample of the green (uncured) sample was molded into a disc with 8 mm diameter and 4 mm height.
  • the disc was loaded in the rheometer with parallel plate geometry inside the force convection oven, which was equilibrated at 80°C. The temperature was quickly raised to 160°C and maintained for 60 minutes. During that time, the elastic modulus is being recorded and plotted as a function of time.
  • the samples were also cured in a hot press heated at 160°C where thin flat specimens were molded for tensile tests. Thermal properties of the AOEDM terpolymers.
  • DSC measurements were used to measure the thermal transitions in the AOEDM terpolymers.
  • Example 13 to Example 18 showed no signs of crystallization/melting, whereas Example 19 and DEDM Example 20 showed a weak crystallization, perhaps due to long ethylene runs along the backbone. Crosslinking of the terpolymers slightly reduces the Tm and Tc values, but does not hinder the crystallization.
  • DSC a 4 mg to 8 mg sample was loaded in a hermetic DSC pan. DSC measurements were carried out using a DSC2500 TM (TA Instruments TM ) with a 10°C/min heating rate.
  • the ODE sample shows the typical crystallization/ melting peaks of polyoctadecene which is associated to side chain crystallization, as described in Macromolecules (2016), v.51, pp.872-883. In contrast, all the ODEM samples showed two peaks during crystallization and two peaks during melting (FIG.5).
  • FIG. 6 shows DSC thermograms of the uncured ODEDM Example 24 samples before and after curing with CPD and sulfur. It is clear that upon crosslinking, the high temperature Tc and Tm peaks disappear, which implies that the side- chain crystallization is hindered. This renders softer elastomers, as the crystallinity is reduced.
  • FIG. 1 The ODEDM sample was measured at two temperatures: at 25°C right below Tm and at 40°C above Tm. Above Tm, the Young modulus is significantly lower, and the extensibility is significantly improved. However, the tensile strength remains the same. A very remarkable behavior observed in the ODEDM sample is the very low hysteresis and the very small tensile set (5.4%) after a deformation of 200 %. Table 3. Tensile properties of DCP-cured AOEDM terpolymers. [0288] Compression tests of the DCP-cured ODEDM (Example 24) sample were carried out at 40°C and compression rate of 0.01 mm/s using the RSA-G2 instrument (TA Instruments) equipped with parallel plates.
  • FIGS. 9A-9C Three levels of DCP were used for these measurements, namely, 0.32, 1.0 and 3.2 phr.
  • the compressive stress-strain curves measured during continuous loading-unloading cycles with increasing maximum strains are shown in FIGS. 9A-9C.
  • the plots show that at DCP levels at and above 1 phr, the hysteresis and compressive set are negligible. This indicate that the deformation of the cured ODEDM is completely reversible after very large deformations (>80% strain). Additionally, very strong strain-hardening response is observed when the strain increases above 40%.
  • FIG.10A shows the maximum stress reached as a function of maximum strain.
  • FIG.10B shows that the maximum strength follows a power law relation with strain and also shows an upward deviation at strains >40%, which is evidence of the strain- hardening behavior.
  • the significant strain hardening is very desirable self-reinforcing phenomena that allows these polymer to resist high loads without penalty on their physical integrity (compression set).
  • FIG. 10C shows the compressive set and the dissipated energy (Edis), as a function of strain.
  • linear ⁇ -olefin-diene copolymers of the present disclosure can have a higher diene content, as compared to conventional diene-containing polymers.
  • the linear ⁇ -olefin-diene copolymers can be optionally crosslinked to provide additional control and manipulation of some polymer properties.
  • linear ⁇ -olefin- diene copolymers of the present disclosure can have low hysteresis and/or low tensile set.
  • Linear ⁇ -olefin-diene copolymers may be suitable for use in, for example, a rubber phase of an ICP.
  • the rubber phase can have less (if any) solvent/oil, as compared to conventional ICPs.
  • solvent/oil that is optionally present in the rubber phase is less prone to being squeezed out during use.
  • Low hysteresis and/or low tensile set may be achieved by linear ⁇ - olefin-diene copolymers without sacrificing impact properties, such as strain hardening properties, that allow the polymers to resist high loads and without penalty of their physical integrity for repeated physical impact(s) during real world use.
  • impact properties such as strain hardening properties
  • the phrases, unless otherwise specified, "consists essentially of” and “consisting essentially of” do not exclude the presence of other steps, elements, or materials, whether or not, specifically mentioned in this specification, so long as such steps, elements, or materials, do not affect the basic and novel characteristics of the present disclosure, additionally, they do not exclude impurities and variances normally associated with the elements and materials used.
  • ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited.
  • ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited.
  • within a range includes every point or individual value between its end points even though not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.
  • compositions, an element or a group of elements are preceded with the transitional phrase “comprising,” it is understood that we also contemplate the same composition or group of elements with transitional phrases “consisting essentially of,” “consisting of,” “selected from the group of consisting of,” or “is” preceding the recitation of the composition, element, or elements and vice versa.

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Abstract

This invention relates to a copolymer comprising about 50 wt% to about 99.9 wt% C6-C60 linear α-olefin units; diene units; and optionally C2-C10 α-olefin comonomer units different than the C6-C60 linear α-olefin units. In at least one embodiment, the copolymer is crosslinked and the crosslinked copolymer has: a tensile set @200% deformation of about 0.1% to about 50% or less; a tensile strength at 40°C of about 50 kPa to about 1,000 kPa; about 1 kJ/m3 to about 10 kJ/m3; an elongation at break of about 10% to about 1,000%; a Young's modulus (at 40°C) of about 50 kPa to about 1,000 kPa; a glass transition temperature (Tg) of about -100°C to about 0°C; a melting temperature (Tm) of about 50°C to about 150°C; and a temperature of crystallization (Tc) of about 10°C to about 150°C.

Description

LINEAR ALPHA-OLEFIN COPOLYMERS AND IMPACT COPOLYMERS THEREOF INVENTORS: Carlos R. Lopez-Barron, Tzu-Pin Lin, and Avery Smith CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims the priority benefit of US Provisional Application No. 62/992483, filed March 20, 2020, the disclosure of which is incorporated herein by reference. FIELD [0002] The present disclosure relates to copolymers comprising C6-C60 linear α-olefin units; diene units; and optionally C2-C10 α-olefin comonomer units different than the C6-C60 linear α-olefin units, impact copolymers prepared from such copolymers and process to produce the same. BACKGROUND [0003] Impact copolymers (ICPs) have a myriad of uses, such as roofing materials, tires, seals, and gaskets. ICPs are characterized as having a rubber phase (“dispersed phase”) dispersed in a continuous phase. Typically, ethylene-propylene copolymers are used as the rubber phase in ICPs. For applications such as in roofing materials, it can be desirable to have ICPs having certain properties, such as a relatively low elastic modulus, which often involves incorporating relatively large amounts of ethylene-propylene (EP) rubber and/or solvent/oil into the impact copolymer. [0004] Regarding modulus of the ICPs, the lower limit of elastic modulus is ultimately determined by the modulus of the rubber, and the desired modulus of the rubber can achieved by the addition of solvent/oil into at least the rubber phase of the ICP. However, repeated compression of the ICP during use can squeeze the solvent/oil out of the ICP, resulting in an ICP having compromised compressive strength and elastic properties. [0005] In addition, hysteresis can be a parameter to examine when assessing a material's impact properties. Hysteresis refers to the energy absorbed when a material is being stretched and the energy that is released when the force is removed. Hysteresis can be an important parameter with tires which increase in pressure during revolution of the wheels. If the tire is underinflated, a ‘blow-out’ can occur. For example, a stress–strain graph for materials such as rubber shows that the behavior as a load (that has been applied to the material) is removed is not the same as the behavior when the load applied to the material is being increased. This difference is referred to as hysteresis, and the curves of the graph are said to form a hysteresis loop. Rubber absorbs more energy during loading than it releases in unloading. The difference is represented by the area of the hysteresis loop. In the context of ICPs, high hysteresis behavior can promote removal of solvent/oil from the ICP because the material has not returned to its size before compacting/stretching. [0006] In addition, tensile set can be a parameter to examine when assessing a material’s impact properties. Tensile set is the extension remaining after a material has been stretched and then allowed to retract, expressed as a percentage of the original length. The material’s ability (or not) to return to its size before stretching is referred to as its tensile set. Tensile set can be important to many commercial rubber products that expand and contract during normal use. For example, seals and gaskets are usually stretched and should return to their original size in order to function properly in the specific application. However, even commercially successful rubbers have a tensile set of 20% or more. [0007] There is a need in the art for polymers having low hysteresis and/or low tensile set that have maintained or improved impact properties, for example, for use in ICPs having less (if any) solvent/oil present in the ICP. [0008] References for citing in an information disclosure statement (37 C.F.R.1.97(h)): U.S. Patent Publication Nos. US 2018/0086526; US 2017/0355840; US 2017/0247536; US 2015/0299455; US 2013/0018150; US 2012/0208962; US 2011/0178249; US 2011/0082258; US 2010/0240818; US 2010/0113698; US 2009/0105374; US 2008/0269388; US 2007/0010616; US 2006/0199911; US 2019/0315931; US 2016/0347914; US 2014/0088263; US 2012/0130011; US 2010/0076121; US 2010/0036038; US 2009/0197995; US 2009/0143550; US 2004/0102591; US 2003/0212226; and US 2003/0171508. SUMMARY [0009] In some embodiments, a copolymer has about 50 wt% to about 99.9 wt% C6-C60 linear α-olefin units, based on the weight of the copolymer; diene units; and optionally C2-C10 α-olefin comonomer units different than the C6-C60 linear α-olefin units. [0010] In some embodiments, a crosslinked copolymer has: a tensile set @ 200% deformation of about 0.1% to about 50% or less; a tensile strength at 40°C of about 50 kPa to about 1,000 kPa; an Edis of about 1 kJ/m3 to about 10 kJ/m3; an elongation at break of about 10% to about 1,000%; a Young’s modulus (at 40°C) of about 50 kPa to about 1,000 kPa; a glass transition temperature (Tg) of about –100°C to about 0°C; a melting temperature (Tm) of about 50°C to about 150°C; and a temperature of crystallization (Tc) of about 10°C to about 150°C. [0011] In some embodiments, an impact copolymer includes from 10 wt% to 80 wt% of a copolymer having about 50 wt% to about 99.9 wt% C6-C60 linear α-olefin units, based on the weight of the copolymer; diene units; and optionally C2-C10 α-olefin comonomer units different than the C6-C60 linear α-olefin units; based on the weight of the impact copolymer; and a polypropylene. [0012] In some embodiments, an article includes an impact copolymer. [0013] In some embodiments, a process to produce an impact copolymer includes combining a first component comprising polypropylene with from 10 wt% to 80 wt% of a copolymer having about 50 wt% to about 99.9 wt% C6-C60 linear α-olefin units, based on the weight of the copolymer; diene units; and optionally C2-C10 α-olefin comonomer units different than the C6-C60 linear α-olefin units, under melt conditions to form a homogenous melt mixture. The process includes cooling the melt mixture to form the impact copolymer comprising the first component as a continuous phase and the second component as a dispersed phase. [0014] In some embodiments, a process to produce a copolymer includes introducing a C6-C60 linear α-olefin, a diene, and optionally C2-C10 α-olefin comonomer (different than the C6-C60 linear α-olefin) to a catalyst system comprising an activator and a tetrahydroindacenyl catalyst compound. BRIEF DESCRIPTION OF THE DRAWINGS [0015] FIG.1 is a graph illustrating cure kinetics at 160°C of AOEDM samples mixed with 1 phr of DCP, according to at least one embodiment. [0016] FIG.2 is a graph illustrating cure kinetics at 160°C of AOEDM samples mixed with 2 phr of sulfur, according to at least one embodiment. [0017] FIG.3 is a graph illustrating cure kinetics of Example 6 with three different curing systems, according to at least one embodiment. [0018] FIG. 4A is a DSC thermogram DEDM Example 20 uncured and cured with DCP and sulfur, according to at least one embodiment (cooling). [0019] FIG 4B is a DSC thermogram DEDM Example 20 uncured and cured with DCP and sulfur, according to at least one embodiment (heating). [0020] FIG. 5 is DSC thermograms of ODE (Example 9) and ODEDM (Example 11 and Example 12) samples (uncured), according to at least one embodiment. [0021] FIG.6 is DSC thermograms of ODEDM (Example 24) uncured and cured samples, according to at least one embodiment. [0022] FIG. 7 is a graph illustrating tensile test of DCP-cured DEDM (Example 20) and ODEDM (Example 24) samples measured at 25°C and 40°C, according to at least one embodiment. [0023] FIG. 8 is a graph illustrating hysteresis test in of DCP-cured ODEDM (Example 24) sample measured at 40°C, according to at least one embodiment. [0024] FIG. 9A is a graph illustrating compressive stress-strain curves of DCP-cured ODEDM (Example 24) with 0.32 phr of DCP curative, according to at least one embodiment. [0025] FIG. 9B is a graph illustrating compressive stress-strain curves of DCP-cured ODEDM (Example 24) with 1 phr of DCP curative, according to at least one embodiment. [0026] FIG. 9C is a graph illustrating compressive stress-strain curves of DCP-cured ODEDM (Example 24) with 3.2 phr of DCP curative, according to at least one embodiment. [0027] FIG. 10A is a graph illustrating maximum stress (kPA) versus maximum strain % of DCP-cured ODEDM (Example 24), according to at least one embodiment. [0028] FIG.10B is a graph illustrating compressive set versus maximum strain % of DCP- cured ODEDM (Example 24), according to at least one embodiment. [0029] FIG.10C is a graph illustrating Edis (kJ/m3) versus maximum strain % of DCP-cured ODEDM (Example 24), according to at least one embodiment. DETAILED DESCRIPTION [0030] The present disclosure generally relates to linear α-olefin-diene copolymers. Copolymers of the present disclosure can be terpolymers including ethylene units. It has been discovered that ethylene units provide spacing between bulkier units of the terpolymer (such as linear α-olefin units and diene units). The linear α-olefin-diene copolymers of the present disclosure can be formed by polymerization using tetrahydroindacenyl catalysts. It has been discovered that, using such catalysts for polymerization, in combination with the use of ethylene monomer, enables increased incorporation of diene units into the polymer backbone, providing linear α-olefin-diene copolymers with a higher diene content, as compared to conventional diene-containing polymers. The linear α-olefin-diene copolymers can be optionally crosslinked to enable additional control and manipulation of some polymer properties. [0031] It has further been discovered that linear α-olefin-diene copolymers of the present disclosure can have low hysteresis behavior and/or low tensile set. For example, commercial copolymers can have a tensile set of at least 20%. However, linear α-olefin-diene copolymers of the present disclosure may have a tensile set of less than 20%, such as less than 15%. [0032] Linear α-olefin-diene copolymers described herein may be suitable for use in, for example, a rubber phase of an ICP. The rubber phase can have less (if any) solvent/oil, as compared to conventional ICPs. For example, conventional ICPs can have, for example, 150 phr of oil. However, copolymers (rubber phases thereof and ICPs thereof) of the present disclosure can be substantially (e.g., completely) free of oil. In addition, solvent/oil that is optionally present in a copolymer/rubber phase of the present disclosure is less prone to being squeezed out during use. Additionally or alternatively, low hysteresis behavior and/or low tensile set can be achieved by the linear α-olefin-diene copolymers disclosed herein without sacrificing impact properties, such as strain hardening properties. Strain hardening is a desirable property in elastomers because it enables the polymers to resist high loads and without penalizing their physical integrity due to repeated loading-unloading deformation cycles and during physical impact(s) during the ICP’s use. [0033] The term “and/or” refers to both the inclusive “and” case and the exclusive “or” case, and such terms are used herein for brevity. For example, a composition comprising “A and/or B” may comprise A alone, B alone, or both A and B; and a composition comprising “A and or B” may comprise A alone, or both A and B. [0034] The percentage of a particular monomer in a polymer is expressed herein as weight percent (wt%) based on the total weight of the polymer present. All other percentages are expressed as weight percent (wt%), based on the total weight of the particular composition present, unless otherwise noted. Room temperature is 25°C ± 2°C and atmospheric pressure is 101.325 kPa unless otherwise noted. [0035] The term “consisting essentially of” in reference to a composition is understood to mean that the composition can include additional compounds other than those specified, in such amounts to the extent that they do not substantially interfere with the essential function of the composition. [0036] For purposes herein a “polymer” refers to a compound having two or more “mer” units, that is, a degree of polymerization of two or more, where the mer units can be of the same or different species. A “homopolymer” is a polymer having mer units that are the same species. A “copolymer” is a polymer having two or more different species of mer units. A “terpolymer” is a polymer having three different species of mer units. “Different” in reference to mer units indicates that the mer units differ from each other by at least one atom or are different isomerically. Unless otherwise indicated, reference to a polymer herein includes a copolymer, a terpolymer, or any polymer comprising a plurality of the same or different species of repeating units. [0037] The term impact copolymer , as used herein, refers to a thermoplastic resin comprising an elastomeric polymer, often referred to as a rubber, dispersed within a polyolefin continuous phase, e.g., polypropylene. Impact copolymers are suitable for transformation by various processing technologies including injection molding, blow molding, film, fiber, sheet extrusion, thermoforming, and the like. An “impact copolymer” may include uncrosslinked components and/or crosslinked components. When one or more components of the impact copolymer are crosslinked (such as a crosslinked linear α-olefin-diene copolymer), the impact copolymer may be referred to as a thermoplastic vulcanizate. [0038] As used herein, the prefixes di- and tri- generally refer to two and three, respectively. Similarly, the prefix “poly-” generally refers to two or more, and the prefix “multi-” to three or more. [0039] The term “residue” or “unit”, as used herein, means the organic structure of the monomer in its as-polymerized form as incorporated into a polymer, e.g., through polymerization of the corresponding monomer. Throughout the specification and claims, reference to the monomer(s) in the polymer is understood to mean the corresponding as- polymerized form or residue of the respective monomer. [0040] For purposes herein, the melting temperature, crystallization temperature, glass transition temperature, etc., are determined by DSC analysis from the second heating ramp by heating of the sample at 10°C/min from 0°C to 300°C. The melting, crystallization, and glass transition temperatures are measured as the midpoint of the respective endotherm or exotherm in the second heating ramp. [0041] For purpose herein, proton NMR spectra are collected using a suitable instrument, e.g., a 500 MHz Varian pulsed Fourier transform NMR spectrometer equipped with a variable temperature proton detection probe operating at 120°C. Typical measurement of the NMR spectrum include dissolving of the polymer sample in 1,1,2,2-tetrachloroethane-d2 (“TCE-d2”) and transferring into a 5 mm glass NMR tube. Typical acquisition parameters are sweep width of 10 KHz, pulse width of 30 degrees, acquisition time of 2 seconds, acquisition delay of 5 seconds and number of scans was 120. Chemical shifts are determined relative to the TCE-d2 signal which was set to 5.98 ppm. [0042] For purposes unless otherwise specified, the herein, average particle size of the dispersed phase within the continuous phase of the composition, also referred to herein as the domain size, is determined using atomic force microscopy (AFM) unless otherwise specified. Unless otherwise specified, the average particle size refers to volume-based particle size in which the measurement is based on the diameter of a sphere that has the same volume as a given particle according to the formula: ^ ^ wherein D = diameter of the representative
Figure imgf000008_0001
sphere; and volume of the particle. [0043] Atomic force microscopy is carried out using a Bruker ICON Atomic Force Microscope or the like. Typical analysis involves the cryo-microtoming of the sample prior to scanning in order to create a smooth surface at -80°C. After microtoming, the samples are purged under N2 in a desiccator before AFM evaluation. Imaging is typically conducted by tuning to the fundamental (1st) mode of the cantilever, setting the amplitude at 1.0 V and the drive frequency to about 5% below the free-air resonance frequency of the cantilever. Calibration is conducted using suitable standards, e.g., Asylum Research reference standard (10 microns x 10 microns pitch grating x 200 nm deep pits) for AFM SQC and X, Y, and Z calibration. Unless otherwise indicated, instrument calibration assumes an accuracy of +/- 2%, with a true value for X-Y within 5% or better for Z. Representative scan sizes include 25x25 µm and 2.5x2.5 µm. [0044] As used herein, components which are melt miscible, also referred to as fully or completely melt miscible, form a homogenous solution under melt conditions, i.e., when heated above the highest melting point of the components present. [0045] For the purposes of the present disclosure, the numbering scheme for the Periodic Table Groups is used as described in Chemical and Engineering News, v.63(5), pg.27 (1985), e.g., a “Group 4 metal” is an element from Group 4 of the Periodic Table, e.g. Hf, Ti, or Zr. [0046] An “olefin,” alternatively referred to as “alkene,” is a linear, branched, or cyclic compound of carbon and hydrogen having at least one carbon-carbon double bond. For purposes of this specification and the claims appended thereto, when a polymer or copolymer is referred to as comprising an olefin, the olefin present in such polymer or copolymer is the polymerized form of the olefin. For example, when a copolymer is said to have an “ethylene” content of 35 wt% to 55 wt%, it is understood that the mer unit in the copolymer is derived from ethylene in the polymerization reaction and said derived units are present at 35 wt% to 55 wt%, based upon the weight of the copolymer. A “polymer” has two or more of the same or different mer units. A “homopolymer” is a polymer having mer units that are the same. A “copolymer” is a polymer having two or more mer units that are different from each other. A “terpolymer” is a polymer having three mer units that are different from each other. “Different” as used to refer to mer units indicates that the mer units differ from each other by at least one atom or are different isomerically. Accordingly, the definition of copolymer, as used herein, includes terpolymers and the like. An “ethylene polymer” or “ethylene copolymer” is a polymer or copolymer comprising at least 50 mol% ethylene derived units, a “propylene polymer” or “propylene copolymer” is a polymer or copolymer comprising at least 50 mol% propylene derived units, and so on. [0047] For purposes of the present disclosure, ethylene shall be considered an α-olefin. [0048] The terms “hydrocarbyl radical,” “hydrocarbyl” and “hydrocarbyl group” are used interchangeably throughout this document. Likewise the terms “group,” “radical,” and “substituent” are also used interchangeably in this document. For purposes of this disclosure, “hydrocarbyl radical” is defined to be a radical, which contains hydrogen atoms and up to 50 carbon atoms and which may be linear, branched, or cyclic, and when cyclic, aromatic or non- aromatic. [0049] Substituted hydrocarbyl radicals are radicals in which at least one hydrogen atom has been substituted with at least one functional group such as NRx 2, ORx, SeRx, TeRx, PRx 2, AsRx2, SbRx2, SRx, BRx and the like or where at least one non-hydrocarbon atom or group has been inserted within the hydrocarbyl radical, such as -O-, -S-, -Se-, -Te-, -N(Rx)-, =N-, -P(Rx)-, =P-, -As(Rx)-, =As-, -Sb(Rx)-, =Sb-, -B(Rx)-, =B- and the like, where Rx is independently a hydrocarbyl or halocarbyl radical, and two or more Rx may join together to form a substituted or unsubstituted saturated, partially unsaturated or aromatic cyclic or polycyclic ring structure. Examples of a substituted hydrocarbyls would include -CH2CH2-O- CH3 and –CH2-NMe2 where the radical is bonded via the carbon atom, but would not include groups where the radical is bonded through the heteroatom such as –OCH2CH3 or –NMe2. [0050] Silylcarbyl radicals are radicals in which one or more hydrocarbyl hydrogen atoms have been substituted with at least one SiR*3 containing group or where at least one –Si(R*)2- has been inserted within the hydrocarbyl radical where R* is independently a hydrocarbyl or halocarbyl radical, and two or more R* may join together to form a substituted or unsubstituted saturated, partially unsaturated or aromatic cyclic or polycyclic ring structure. [0051] Substituted silylcarbyl radicals are radicals in which at least one hydrogen atom has been substituted with at least one functional group such as NR*2, OR*, SeR*, TeR*, PR*2, AsR*2, SbR*2, SR*, BR*2, GeR*3, SnR*3, PbR*3 and the like or where at least one non- hydrocarbon atom or group has been inserted within the silylcarbyl radical, such as -O-, -S-, -Se-, -Te-, -N(R*)-, =N-, -P(R*)-, =P-, -As(R*)-, =As-, -Sb(R*)-, =Sb-, -B(R*)-, =B-, -Ge(R*)2-, -Sn(R*)2-, -Pb(R*)2- and the like, where R* is independently a hydrocarbyl or halocarbyl radical, and two or more R* may join together to form a substituted or unsubstituted saturated, partially unsaturated or aromatic cyclic or polycyclic ring structure. Substituted silylcarbyl radicals are only bonded via a carbon or silicon atom. [0052] Germylcarbyl radicals are radicals in which one or more hydrocarbyl hydrogen atoms have been substituted with at least one GeR*3 containing group or where at least one –Ge(R*)2- has been inserted within the hydrocarbyl radical where R* independently a hydrocarbyl or halocarbyl radical, and two or more R* may join together to form a substituted or unsubstituted saturated, partially unsaturated or aromatic cyclic or polycyclic ring structure. Substituted germylcarbyl radicals are only bonded via a carbon or germanium atom. [0053] Substituted germylcarbyl radicals are radicals in which at least one hydrogen atom has been substituted with at least one functional group such as NR*2, OR*, SeR*, TeR*, PR*2, AsR*2, SbR*2, SR*, BR*2, SiR*3, SnR*3, PbR*3 and the like or where at least one non- hydrocarbon atom or group has been inserted within the germylcarbyl radical, such as -O-, -S-, -Se-, -Te-, -N(R*)-, =N-, -P(R*)-, =P-, -As(R*)-, =As-, -Sb(R*)-, =Sb-, -B(R*)-, =B-, -Si(R*)2-, -Sn(R*)2-, -Pb(R*)2- and the like, where R* is independently a hydrocarbyl or halocarbyl radical, and two or more R* may join together to form a substituted or unsubstituted saturated, partially unsaturated or aromatic cyclic or polycyclic ring structure. [0054] Halocarbyl radicals are radicals in which one or more hydrocarbyl hydrogen atoms have been substituted with at least one halogen (e.g. F, Cl, Br, I) or halogen-containing group (e.g. CF3). [0055] Substituted halocarbyl radicals are radicals in which at least one halocarbyl hydrogen or halogen atom has been substituted with at least one functional group such as NR*2, OR*, SeR*, TeR*, PR*2, AsR*2, SbR*2, SR*, BR*2 and the like or where at least one non- carbon atom or group has been inserted within the halocarbyl radical such as -O-, -S-, -Se-, -Te-, -N(R*)-, =N-, -P(R*)-, =P-, -As(R*)-, =As-, -Sb(R*)-, =Sb-, -B(R*)-, =B- and the like, where R* is independently a hydrocarbyl or halocarbyl radical provided that at least one halogen atom remains on the original halocarbyl radical. Additionally, two or more R* may join together to form a substituted or unsubstituted saturated, partially unsaturated or aromatic cyclic or polycyclic ring structure. Substituted halocarbyl radicals are only bonded via a carbon atom. [0056] A heteroatom is an atom other than carbon or hydrogen. [0057] The term “aryl” or “aryl group” means a monocyclic or polycyclic aromatic ring and the substituted variants thereof, including but not limited to, phenyl, naphthyl, 2-methyl- phenyl, xylyl, 4-bromo-xylyl. Likewise “heteroaryl” means an aryl group where a ring carbon atom (or two or three ring carbon atoms) has been replaced with a heteroatom, such as N, O, or S. The term substituted aryl means: 1) an aryl group where a hydrogen has been replaced by a substituted or unsubstituted hydrocarbyl group, a substituted or unsubstituted halocarbyl group, a substituted or unsubstituted silylcarbyl group, or a substituted or unsubstituted germylcarbyl group. The term “substituted heteroaryl” means: 1) a heteroaryl group where a hydrogen has been replaced by a substituted or unsubstituted hydrocarbyl group, a substituted or unsubstituted halocarbyl group, a substituted or unsubstituted silylcarbyl group, or a substituted or unsubstituted germylcarbyl group. [0058] For nomenclature purposes, the following numbering schemes are used for indenyl, trihydro-s-indacenyl, trihydro-as-indacenyl, tetrahydro-s-indacenyl and tetrahydro-as- indacenyl ligands. . [0059] As used herein, Mn is number average molecular weight, Mw is weight average molecular weight, and Mz is z average molecular weight, wt% is weight percent, and mol% is mole percent. Molecular weight distribution (MWD), also referred to as polydispersity, is defined to be Mw divided by Mn. Unless otherwise noted, all molecular weight units (e.g., Mw, Mn, Mz) are g/mol. The following abbreviations may be used herein: ENB is 5-ethylidene-2-norbornene, Me is methyl, Et is ethyl, Pr is propyl, cPr is cyclopropyl, nPr is n-propyl, iPr is isopropyl, Bu is butyl, nBu is normal butyl, iBu is isobutyl, sBu is sec-butyl, tBu is tert-butyl, Oct is octyl, Ph is phenyl, Bn is benzyl, Cp is cyclopentadienyl, Ind is indenyl, and MAO is methylalumoxane. [0060] For purposes herein, a “catalyst system” is the combination of at least one catalyst compound, at least one activator, an optional co-activator, and an optional support material. For purposes of the present disclosure and the claims thereto, when catalyst systems are described as comprising neutral stable forms of the components, it is well understood by one of ordinary skill in the art, that the ionic form of the component is the form that reacts with the monomers to produce polymers. [0061] In the description herein, the metallocene catalyst may be described as a catalyst precursor, a pre-catalyst compound, metallocene catalyst compound or a transition metal compound, and these terms are used interchangeably. [0062] A metallocene catalyst is defined as an organometallic transition metal compound with at least one ^-bound cyclopentadienyl moiety (or substituted cyclopentadienyl moiety) bound to a transition metal. [0063] For purposes of the present disclosure in relation to metallocene catalyst compounds, the term “substituted” means that one or more hydrogen atoms have been replaced with a hydrocarbyl, heteroatom (such as a halide), or a heteroatom containing group, (such as silylcarbyl, germylcarbyl, halocarbyl, etc.). For example, bis (methyl cyclopentadiene)ZrCl2 is a substituted metallocene where a hydrogen on the Cp group is replaced with a methyl group. [0064] For purposes of the present disclosure, “alkoxides” include those where the alkyl group is a C1 to C10 hydrocarbyl. The alkyl group may be straight chain, branched, or cyclic. The alkyl group may be saturated or unsaturated. In some embodiments, the alkyl group may comprise at least one aromatic group. Copolymers [0065] Copolymers of the present disclosure comprise a linear α-olefin, a diene, and optionally a C2-C10 α-olefin comonomer different than the C6-C60 linear α-olefin (such as ethylene). “Different” in reference to linear α-olefins indicates that the linear α-olefin units differ from each other by at least one atom or are different isomerically. In one or more embodiments, a copolymer has a linear α-olefin, a diene, and optionally ethylene. For example, a copolymer may have greater than or equal to about 50 wt% and less than or equal to about 99.9 wt% C6-C60 linear α-olefin, based on the total weight of the copolymer. [0066] A copolymer can have a linear α-olefin content of about 50 wt% to about 99.9 wt%, such as about 60 wt% to about 99.9 wt%, such as from about 70 wt% to about 99.9 wt%, such as from about 80 wt% to about 99.5 wt%, such as from about 85 wt% to about 99 wt%, such as from about 90 wt% to about 99 wt%, such as from about 93 wt% to about 99 wt%, such as from about 95 wt% to about 99 wt%, based on the weight of the copolymer. Linear alpha olefins (LAOs) can be substituted or unsubstituted C6-C60 LAOs, such as C8-C50 LAOs, such as C10-C40 LAOs, such as C12-C30 LAOs, such as C14-C26 LAOs, such as C16–C26 LAOs, such as C18-C26 LAOs, such as C20-C26 LAOs. LAOs can have some branching. For example, an LAO may have one or more pendant methyl or ethyl substitutions along the LAO backbone. In some embodiments, an LAO is free of branching, e.g. is entirely linear. In at least one embodiment, a copolymer has linear α-olefin units selected from 1-octene, 1-decene, 1-undecene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene, 1-icosene, 1-henicosene, 1-docosene, 1-tricosene, 1-tetracosene, 1-pentacosene, and combination(s) thereof. [0067] A copolymer can have a diene content of about 0.1 wt% to about 40 wt%, such as from about 0.1 wt% to about 30 wt%, such as from about 0.1 wt% to about 20 wt%, such as from about 0.1 wt% to about 10 wt%, such as from about 0.5 wt% to about 10 wt%, such as from about 1 wt% to about 10 wt%, such as from about 1.5 wt% to about 8 wt%, such as from about 2 wt% to about 6 wt%, such as from about 2 wt% to about 5 wt%, such as from about 3 wt% to about 5 wt%, based on the weight of the copolymer. Dienes can be substituted or unsubstituted dienes selected from C4-C60 dienes, such as C5-C50 dienes, such as C5-C40 dienes, such as C5-C30 dienes, such as C5-C20 dienes, such as C6-C15 dienes, such as C6-C10 dienes, such as C7-C9 dienes, such as a substituted or unsubstituted C7 diene, C8 diene, or C9 diene. In at least one embodiment, a copolymer has diene units of a C7 diene. In at least one embodiment, a diene is a substituted or unsubstituted α,Ω-diene (e.g., the diene units of the copolymer are formed from di-vinyl monomers). The dienes can be linear di-vinyl monomers. In at least one embodiment, a diene is selected from butadiene, pentadiene, hexadiene, heptadiene, octadiene, nonadiene, decadiene, undecadiene, dodecadiene, tridecadiene, tetradecadiene, pentadecadiene, hexadecadiene, heptadecadiene, octadecadiene, nonadecadiene, icosadiene, heneicosadiene, docosadiene, tricosadiene, tetracosadiene, pentacosadiene, hexacosadiene, heptacosadiene, octacosadiene, nonacosadiene, triacontadiene, and combination(s) thereof. In some embodiments, a diene is selected from 1,6-heptadiene, 1,7-octadiene, 1,8-nonadiene, 1,9-decadiene, 1,10-undecadiene, 1,11-dodecadiene, 1,12-tridecadiene, 1,13-tetradecadiene, and combination(s) thereof. In at least one embodiment, a diene is selected from cyclopentadiene, vinylnorbornene, norbornadiene, 5-ethylidene-2-norbornene, 5-vinyl-2- norbornene, divinylbenzene, dicyclopentadiene, and combination(s) thereof. In at least one embodiment, a copolymer has diene units of 5-ethylidene-2-norbornene. [0068] A copolymer can have C2-C10 α-olefin comonomer content (different than the C6-C60 linear α-olefin content) of about 0.1 wt% to about 40 wt%, such as from about 0.1 wt% to about 30 wt%, such as from about 0.1 wt% to about 20 wt%, such as from about 1 wt% to about 15 wt%, such as from about 1 wt% to about 10 wt%, such as from about 1.5 wt% to about 9 wt%, such as from about 2 wt% to about 8 wt%, such as from about 1.5 wt% to about 2.5 wt%, alternatively from about 8 wt% to about 15 wt%, such as from about 8 wt% to about 12 wt%, based on the weight of the copolymer. [0069] In at least one embodiment, a copolymer has one or more of: an Mw value of 5,000 g/mol or greater, such as from about 10,000 g/mol to about 2,000,000 g/mol, such as from about 50,000 g/mol to about 2,000,000 g/mol, such as from about 100,000 g/mol to about 1,000,000 g/mol, such as from about 100,000 g/mol to about 500,000 g/mol, such as from about 150,000 g/mol to about 300,000 g/mol, such as from about 200,000 g/mol to about 300,000 g/mol, alternatively from about 400,000 g/mol to 500,000 g/mol; an Mn value of 5,000 g/mol or greater, such as from about 5,000 to about 1,000,000, such as about 40,000 g/mol to about 300,000 g/mol, such as from about 60,000 g/mol to about 250,000 g/mol, such as from about 70,000 g/mol to about 200,000 g/mol, such as from about 80,000 g/mol to about 150,000 g/mol, such as from about 90,000 g/mol to about 100,000 g/mol, alternatively from about 100,000 g/mol to about 140,000 g/mol; and or an Mz value of 20,000 g/mol or greater, such as from about 20,000 to about 6,000,000, such as about 300,000 g/mol to about 4,000,000 g/mol, such as from about 1,000,000 to about 2,500,000 g/mol, alternatively from about 3,500,000 g/mol to about 4,000,000 g/mol. [0070] In at least one embodiment, the copolymer has an Mw/Mn (MWD) value of 1 to 10, such as from 1 to 5, such as from 1.5 to about 4, such as from 2 to about 3. [0071] In at least one embodiment, the copolymer has a glass transition temperature (Tg) of -30°C or less, such as from about -30°C to about -100°C, such as from about -50°C to about -70°C. [0072] In at least one embodiment, the copolymer has a crystallization temperature (Tc) of at least 0°C, such as from about 0°C to about 100°C, such as from about 20°C to about 80°C, such as from about 60°C to about 80°C. GPC 4-D [0073] For purposes of the claims, and unless otherwise indicated, the distribution and the moments of molecular weight (Mw, Mn, Mz, Mw/Mn, etc.), the comonomer content and the branching index (g') are determined by using a high temperature Gel Permeation Chromatography (Polymer Char GPC-IR) equipped with a multiple-channel band-filter based Infrared detector IR5 with a multiple-channel band filter based infrared detector ensemble IR5 with band region covering from about 2,700 cm-1 to about 3,000 cm-1 (representing saturated C-H stretching vibration), an 18-angle light scattering detector and a viscometer. Three Agilent PLgel 10-µm Mixed-B LS columns are used to provide polymer separation. Reagent grade 1,2,4-trichlorobenzene (TCB) (from Sigma-Aldrich) comprising ~300 ppm antioxidant BHT can be used as the mobile phase at a nominal flow rate of ~1.0 mL/min and a nominal injection volume of ~200 μL. The whole system including transfer lines, columns, and detectors can be contained in an oven maintained at ~145°C. A given amount of sample can be weighed and sealed in a standard vial with ~10 μL flow marker (heptane) added thereto. After loading the vial in the auto-sampler, the oligomer or polymer may automatically be dissolved in the instrument with ~8 mL added TCB solvent at ~160°C with continuous shaking. The sample solution concentration can be from ~0.2 mg/ml to ~2.0 mg/ml, with lower concentrations used for higher molecular weight samples. The concentration, c, at each point in the chromatogram can be calculated from the baseline-subtracted IR5 broadband signal, I, using the equation: c=αI, where α is the mass constant determined with polyethylene or polypropylene standards. The mass recovery can be calculated from the ratio of the integrated area of the concentration chromatography over elution volume and the injection mass which is equal to the pre- determined concentration multiplied by injection loop volume. The conventional molecular weight (IR MW) is determined by combining universal calibration relationship with the column calibration which is performed with a series of monodispersed polystyrene (PS) standards ranging from 700 to 10M gm/mole. The MW at each elution volume is calculated with following equation: log ^ = log^^^^/^^ ^ + 1 + ^^^ + 1 ^ + 1 log ^^^ where the variables with subscript "PS" stand for polystyrene while those without a subscript
Figure imgf000015_0001
are for the test samples. In this method, αPS = 0.7362 and KPS = 0.0000957, α and K for other materials are as calculated and published in literature (Sun, T. et al. Macromolecules 2001, v.34, pg.6812), except that “ α” and “K” are α = 0.738 and K = 0.000072 for linear octadecene– ethylene–diene terpolymers, α = 0.737 and K = 0.000117 for decene-ethylene-diene terpolymers, α = 0.705 and K = 0.0002288 for linear propylene polymers, α = 0.695 and K = 0.000181 for linear butene polymers, α is 0.695 and K is 0.000579*(1- 0.0087*w2b+0.000018*(w2b)^2) for ethylene–butene copolymer where w2b is a bulk weight percent of butene comonomer, α is 0.695 and K is 0.000579*(1-0.0075*w2b) for ethylene– hexene copolymer where w2b is a bulk weight percent of hexene comonomer, α is 0.695 and K is 0.000579*(1-0.0077*w2b) for ethylene–octene copolymer where w2b is a bulk weight percent of octene comonomer, and α is 0.695 and K is 0.000579 for all other linear ethylene polymers. Concentrations are expressed in g/cm3, molecular weight is expressed in g/mole, and intrinsic viscosity (hence K in the Mark–Houwink equation) is expressed in dL/g unless otherwise noted. [0074] The comonomer composition is determined by the ratio of the IR5 detector intensity corresponding to CH2 and CH3 channel calibrated with a series of PE and PP homo/copolymer standards whose nominal value are predetermined by NMR or FTIR. In particular, this provides the methyls per 1,000 total carbons (CH3/1000TC) as a function of molecular weight. The short-chain branch (SCB) content per 1000TC (SCB/1000TC) is then computed as a function of molecular weight by applying a chain-end correction to the CH3/1000TC function, assuming each chain to be linear and terminated by a methyl group at each end. The weight % comonomer is then obtained from the following expression in which α is 0.3, 0.4, 0.6, 0.8, and so on for C3, C4, C6, C8, and so on co-monomers, respectively: w2 = f ∗ SCB/1000TC. [0075] The bulk composition of the polymer from the GPC-IR and GPC-4D analyses is obtained by considering the entire signals of the CH3 and CH2 channels between the integration limits of the concentration chromatogram. First, the following ratio is obtained Bulk IR ratio = Area of CH3 signal within integration limits Area of CH2 signal within integration limits. [0076] Then the
Figure imgf000016_0001
same calibration of the CH3 and CH2 signal ratio, as mentioned previously in obtaining the CH3/1000TC as a function of molecular weight, is applied to obtain the bulk CH3/1000TC. A bulk methyl chain ends per 1000TC (bulk CH3end/1000TC) is obtained by weight-averaging the chain-end correction over the molecular-weight range. Then w2b = f ∗ bulk CH3/1000TC bulk SCB/1000TC = bulk CH3/1000TC − bulk CH3end/1000TC and bulk SCB/1000TC is converted to bulk α2 in the same manner as described above. [0077] The LS detector is the 18-angle Wyatt Technology High Temperature DAWN HELEOSII. The LS molecular weight (M) at each point in the chromatogram is determined by analyzing the LS output using the Zimm model for static light scattering (Light Scattering from Polymer Solutions; Huglin, M. B., Ed.; Academic Press, 1972.): K o c 1 α α2A 2 c . α R ^ α ^ MP ^ α ^ [0078] Here, ΔR(θ) is the em
Figure imgf000016_0002
easured excess Ray leigh scattering intensity at scattering angle θ, c is the polymer concentration determined from the IR5 analysis, A2 is the second virial coefficient, P(θ) is the form factor for a monodisperse random coil, and Ko is the optical constant for the system: 4 α2n2(dn/dc ) 2 K o ^ α 4 N where NA is Avogadro’s number,
Figure imgf000016_0003
and (dn/dc) is the refractive index increment for the system. The refractive index, n = 1.500 for TCB at 145°C and λ = 665 nm. For analyzing polyethylene homopolymers, ethylene-hexene copolymers, and ethylene-octene copolymers, dn/dc = 0.1048 ml/mg and A2 = 0.0015; for analyzing ethylene-butene copolymers, dn/dc = 0.1048*(1-0.00126*w2) ml/mg and A2 = 0.0015 where w2 is weight percent butene comonomer. [0079] A high temperature Agilent (or Viscotek Corporation) viscometer, which has four capillaries arranged in a Wheatstone bridge configuration with two pressure transducers, is used to determine specific viscosity. One transducer measures the total pressure drop across the detector, and the other, positioned between the two sides of the bridge, measures a differential pressure. The specific viscosity, ηs, for the solution flowing through the viscometer is calculated from their outputs. The intrinsic viscosity, [η], at each point in the chromatogram is calculated from the equation [η]= ηs/c, where c is concentration and is determined from the IR5 broadband channel output. The viscosity MW at each point is calculated asM αK PSM ^ PS ^1 [ α ] , where αps is 0.67 and Kps is 0.000175. [0080] The branching index (g'vis) is calculated using the output of the GPC-IR5-LS-VIS method as follows. The average intrinsic viscosity, [η]avg, of the sample is calculated by: c [ α ] i ^ ^ ^ i avg α ^ ^ where the summations are over the chromatographic slices, i, between the integration limits.
Figure imgf000017_0001
[ α ] The branching index g'vis is defined as g ' vis α avg , where M is the viscosity-average KM ^ v v molecular weight based on molecular we
Figure imgf000017_0002
ights determined by LS analysis and the K and α are for the reference linear polymer, which are, for purposes of this present disclosure and claims thereto, α = 0.738 and K = 0.000072 for linear octadecene–ethylene–diene terpolymers, and α = 0.737 and K = 0.000117 for decene-ethylene-diene terpolymers, α = 0.705 and K = 0.0002288 for linear propylene polymers, α = 0.695 and K = 0.000181 for linear butene polymers, α is 0.695 and K is 0.000579*(1-0.0087*w2b+0.000018*(w2b)^2) for ethylene– butene copolymer where w2b is a bulk weight percent of butene comonomer, α is 0.695 and K is 0.000579*(1-0.0075*w2b) for ethylene–hexene copolymer where w2b is a bulk weight percent of hexene comonomer, α is 0.695 and K is 0.000579*(1-0.0077*w2b) for ethylene– octene copolymer where w2b is a bulk weight percent of octene comonomer, and α is 0.695 and K is 0.000579 for all other linear ethylene polymers. Concentrations are expressed in g/cm3, molecular weight is expressed in g/mole, and intrinsic viscosity (hence K in the Mark– Houwink equation) is expressed in dL/g unless otherwise noted. Calculation of the w2b values is as discussed above. Vulcanization [0081] The linear α-olefin-diene copolymers can be vulcanized by employing a variety of curatives to form crosslinked copolymers. Exemplary curatives can include ultraviolet cure, sulfur cure systems, phenolic resin cure systems, peroxide cure systems, silicon-containing cure systems, such as hydrosilylation and silane grafting / moisture cure. Dynamic vulcanization can occur in the presence of the polyolefin (of a continuous phase), or the polyolefin can be added after dynamic vulcanization (e.g., post added), or both (e.g., some polyolefin can be added prior to vulcanization and some polyolefin can be added after vulcanization). [0082] Vulcanization can be effected by mixing the copolymer, optional polyolefin (e.g., polypropylene), and curative(s) at elevated temperature in conventional mixing equipment such as roll mills, stabilizers, Banbury mixers, Brabender mixers, continuous mixers, mixing extruders and the like. Methods for preparing TPV compositions, for example, are described in US Pat. Nos.4,311,628, 4,594,390, 6,503,984, and 6,656,693 (which are incorporated herein by reference), although methods employing low shear rates can also be used. Multiple-step processes can also be employed whereby ingredients, such as additional thermoplastic component (polyolefin), can be added after dynamic vulcanization has been achieved as disclosed in International Application No. PCT/US2004/030517, which is incorporated herein by reference. [0083] In some embodiments, a process for the preparation of the TPV composition (and/or ICP composition) can include melt processing under shear conditions of at least one thermoplastic component, at least one rubber component, and at least one curing agent. In some embodiments, the melt processing can be performed under high shear conditions. Shear conditions are similar to conditions that exist when the TPV compositions (and/or ICP compositions) are produced using common melt processing equipment such as Brabender or Banbury mixers (lab scale instruments) and commercial twin-screw extruders. [0084] The word shear is added to indicate that the TPV compositions (and/or ICP compositions) can be made by mixing under high shear temperature and intense mixing. [0085] As noted above, the TPV (or ICP) compositions are dynamically vulcanized by a variety of methods including employing a cure system, where the cure system comprises a curative. [0086] In some embodiments, useful peroxide curatives can include organic peroxides. Examples of organic peroxides can include di-tert-butyl peroxide, dicumyl peroxide, t-butylcumyl peroxide, α,α-bis(tert-butylperoxy) diisopropyl benzene, 2,5-dimethyl-2,5-di(t- butylperoxy)hexane (DBPH), 1,1-di(tert-butylperoxy)-3,3,5-trimethyl cyclohexane, n-butyl-4- 4-bis(tert-butylperoxy) valerate, benzoyl peroxide, lauroyl peroxide, dilauroyl peroxide, 2,5-dimethyl-2,5-di(tert-butylperoxy) hexyne-3, and mixtures thereof. Also, diaryl peroxides, ketone peroxides, peroxydicarbonates, peroxyesters, dialkyl peroxides, hydroperoxides, peroxyketals and mixtures thereof may be used. Useful peroxides and their methods of use in vulcanization are disclosed in US Pat. No. 5,656,693, which is incorporated herein by reference. [0087] In some embodiments, the peroxide curatives can be employed in conjunction with a coagent. Examples of coagents can include triallylcyanurate, triallyl isocyanurate, triallyl phosphate, sulfur, N-phenyl bis-maleamide, zinc diacrylate, zinc dimethacrylate, divinyl benzene, 1,2-polybutadiene, trimethylol propane trimethacrylate, tetramethylene glycol diacrylate, trifunctional acrylic ester, dipentaerythritolpentacrylate, polyfunctional acrylate, retarded cyclohexane dimethanol diacrylate ester, polyfunctional methacrylates, acrylate and methacrylate metal salts, and oximes such as quinone dioxime. The mixing and dynamic vulcanization may be carried out in a nitrogen atmosphere. [0088] Alternatively, a sulfur source may be used to effect crosslinking. Examples of sulfur sources include elemental sulfur. [0089] A copolymer (or ICP thereof) may undergo crosslinking to form a crosslinked copolymer (or a TPV) at elevated temperatures. In some embodiments, the crosslinking may take place at a temperature of about 150°C or greater, such as about 160°C or greater, about 170°C or greater, about 180°C or greater, about 190°C or greater, about 200°C or greater, about 210°C or greater, about 220°C or greater, about 230°C or greater, about 240°C or greater, or about 250°C or greater. [0090] Alternatively, crosslinking may be performed by exposing the copolymer (or ICP thereof) to electromagnetic radiation having a frequency greater than that of visible light, such as for example near ultraviolet radiation, extreme ultraviolet radiation, soft x-rays, hard x-rays, gamma rays, and high-energy gamma rays. In some embodiments, crosslinking is accomplished by electron beam radiation, or "e-beam" radiation. [0091] E-beam radiation is a form of ionizing energy that is generally characterized by its low penetration and high dose rates. The electrons can be generated by equipment referred to as accelerators which are capable of producing beams that are either pulsed or continuous. The term "beam" is meant to include any area exposed to electrons, which may range from a focused point to a broader area, such as a line or field. The electrons are produced by a series of cathodes (electrically heated tungsten filaments) that generate a high concentration of electrons. These electrons are then accelerated across a potential. The accelerating potential is typically in the keV to MeV range (where eV denotes electron volts), depending on the depth of penetration required. [0092] Suitable e-beam equipment is available from E-BEAM Services, Inc., or from PCT Engineered Systems, LLC. Effective irradiation is generally carried out at a dosage from about 10 kGy to about 100 kGy, or from about 20 to about 90 kGy, or from about 30 to about 80 kGy, or from about 50 to about 60 kGy. In a particular aspect of this embodiment, the irradiation is carried out at room temperature. [0093] A photo-initiator may be added to (e.g., mixed with) the copolymer (or ICP) to promote crosslinking upon exposure to electromagnetic radiation. Suitable photo-initiators include ketones (such as 1-hydroxycyclohexyl phenyl ketone), 2,2-Diethoxyacetophenone, 4′-Hydroxy-3′,5′-dimethylacetophenone, 2,2-Dimethoxy-2-phenylacetophenone, or 1-Benzoylcyclohexanol. [0094] Advantageously, the amount of additive (such as peroxide or sulfur source) or photo-initiator (such as a ketone) can be kept low while providing sufficient crosslinking. For example, an amount of additive/photo-initiator can be from about 0.1 wt% to about 10 wt%, such as from about 0.5 wt% to about 5 wt%, such as from about 1 wt% to about 3 wt%, based on the weight of the copolymer (or the rubber in the ICP thereof). In some embodiments, an amount of additive/photo-initiator can be from about 0.1 pounds per hundred rubber (phr) to about 10 phr, such as from about 0.5 phr to about 5 phr, such as from about 1 phr to about 3 phr, based on the weight of the copolymer (or the rubber in the ICP thereof). [0095] In some embodiments, the copolymer can be crosslinked to produce finely dispersed rubber domains in a continuous phase. For example, in some embodiments, the copolymer is partially or fully (completely) crosslinked before an extrusion stage. A method for determining the degree of crosslinking is disclosed in US Pat. No. 4,311,628, which is incorporated herein by reference. In some embodiments, the copolymer has a degree of crosslinking where not more than about 5.9 wt%, such as not more than about 5 wt%, such as not more than about 4 wt%, such as not more than about 3 wt% is extractable by cyclohexane at 23°C as described in US Pat. Nos. 5,100,947 and 5,157,081, which are incorporated herein by reference. In these or other embodiments, the copolymer is crosslinked to an extent where greater than about 94 wt%, such as greater than about 95 wt%, such as greater than about 96 wt%, such as greater than about 97 wt% by weight of the copolymer is insoluble in cyclohexane at 23°C. Alternately, in some embodiments, the copolymer has a degree of cure such that the crosslink density is at least 4×10−5 moles per milliliter of elastomer, such as at least 7×10−5 moles per milliliter of copolymer, such as at least 10×10−5 moles per milliliter of copolymer. See also “Crosslink Densities and Phase Morphologies in Dynamically Vulcanized TPEs,” by Ellul et al., Rubber Chemistry and Technology, v.68, pp.573-584 (1995). [0096] A “partially vulcanized” copolymer is one where more than 5 weight percent (wt%) of the crosslinkable copolymer is extractable in boiling xylene, subsequent to vulcanization, e.g., crosslinking of the rubber phase of a TPV. For example, in a TPV including a partially vulcanized copolymer at least 5 wt% and less than 20 wt%, or 30 wt%, or 50 wt% of the crosslinkable copolymer can be extractable from the specimen of the TPV in boiling xylene. [0097] Despite a copolymer being partially or fully cured in some embodiments, blends can be processed and reprocessed by plastic processing techniques such as extrusion, injection molding, blow molding, and compression molding. [0098] In at least one embodiment, the copolymer is in the form of a thermoplastic vulcanizate including the crosslinked copolymer and a polyolefin (such as a polypropylene). The copolymer can be in the form of finely-divided and well-dispersed particles of vulcanized or cured copolymer within a continuous phase. In some embodiments, a co-continuous morphology or a phase inversion can be achieved. Crosslinked Copolymers [0099] Tensile properties are measured using an RSA-G2 solids analyzer (TA Instruments). A plaque of copolymer sample with 0.5 mm thickness is molded and cured (vulcanized) using a hot press equilibrated at 160°C. Small dogbone specimens (5 mm X 5 mm) are cut from the cure plaques for the tensile tests. The dogbones are mounted on the RSA- G2 using film-gripping tools, and the temperature is equilibrated to 40°C for 5 minutes, using the RSA-G2 forced-convection oven. Two tensile tests are performed, namely, (1) tensile to break and (2) hysteresis. For the tensile to break test, the samples are uniaxially deformed with a linear velocity of 100 microns/s until they break. The tensile strength is the maximum stress measured during the deformation, before the specimen breaks. For the hysteresis test, the sample is deformed to 200% strain, after which point the load is immediately reversed to 0% strain. The tensile set is the permanent deformation of the specimen after one loading- unloading cycle. [0100] In some embodiments, a crosslinked copolymer can have a tensile set @200% deformation of 50% or less, such as about 40% or less, such as about 20% or less, such as about 5% or less. In at least one embodiment, a crosslinked copolymer can exhibit a tensile set @200% deformation of about 0.1% to about 50%, such as from about 1% to about 30%, such as from about 2% to about 20%, such as from about 3% to about 15%, such as from about 3% to about 10%, such as from about 3% to about 7%. [0101] In some embodiments, a crosslinked copolymer can have a tensile strength at 40°C of 60 kPa or more, such as about 150 kPa or more, such as about 350 kPa or more, such as about 500 kPa or more. In at least one embodiment, a crosslinked copolymer can exhibit a tensile strength at 40°C of about 50 kPa to about 1,000 kPa, such as from about 100 kPa to about 750 kPa, such as from about 200 kPa to 700 kPa, such as from about 300 kPa to about 700 kPa, such as from about 400 kPa to about 650 kPa. [0102] In some embodiments, a crosslinked copolymer can have a dissipated energy (Edis) of 1 kJ/m3 or more, such as about 10 kJ/m3 or more, such as about 50 kJ/m3 or more, such as about 100 kJ/m3 or more. In at least one embodiment, a crosslinked copolymer can exhibit an Edis of about 1 kJ/m3 to about 200 kJ/m3, such as from about 1 kJ/m3 to about 150 kJ/m3, such as from about 1 kJ/m3 to 125 kJ/m3, such as from about 50 kJ/m3 to about 125 kJ/m3, such as from about 75 kJ/m3 to about 100 kJ/m3. The dissipated energy (Edis) is computed as the difference between the integrated area of the stress-strain curve corresponding to the loading and the integrated area of the stress-strain curve corresponding to the unloading during one hysteresis cycle. [0103] In some embodiments, a crosslinked copolymer can have an elongation at break at 23°C of 10% or more, such as about 100% or more, such as about 250% or more, such as about 500% or more. In at least one embodiment, a crosslinked copolymer can exhibit an elongation at break of about 10% to about 1,000%, such as from about 100% to about 900%, such as from about 200% to about 800%, such as from about 300% to about 700%, such as from about 400% to about 600%, such as from about 400% to about 500%, alternatively from about 150% to about 250%. [0104] In some embodiments, a crosslinked copolymer can exhibit a Young’s modulus (at 40°C) of about 50 kPa or more, such as about 100 kPa or more, such as about 500 kPa or more. The Young’s modulus is defined as the stress measured at 1% strain divided by 100. In at least one embodiment, a crosslinked copolymer can exhibit a Young’s modulus (at 23°C) of about 50 kPa to about 1,000 kPa, such as from about 100 kPa to about 900 kPa, such as from about 200 kPa to about 800 kPa, such as from about 300 kPa to about 700 kPa, such as from about 400 kPa to about 600 kPa, such as from about 500 kPa to about 600 kPa. [0105] Tg is measured as the middle temperature at the inflection point measured by DSC. In some embodiments, a crosslinked copolymer can have a Tg of about 0°C or less, such as about –25°C or less, such as about –35°C or less, such as about –50°C or less. In at least one embodiment, a crosslinked copolymer can have a Tg of about –100°C to about 0°C, such as from about –80°C to about –25°C, such as from about –70°C to about –35°C, such as from about –70°C to about –60°C. [0106] In some embodiments, a crosslinked copolymer can have an inherent modulus (Gno) of about 5 kPa to about 1,000 kPa, such as from about 10 kPa to about 500 kPa, such as from about 10 kPa to about 250 kPa, such as from about 20 kPa to about 50 kPa, alternatively from about 200 kPa to about 300 kPa. The curing kinetics can be measured in an ARES-G2 rheometer (TA Instruments). A small sample of the green (uncured) sample can be molded into a disc with 8 mm diameter and 4 mm height. The disc can be loaded in the rheometer with parallel plate geometry inside the force convection oven, which is equilibrated at 80°C. The temperature can be quickly raised to 160°C and maintained for 60 minutes. During that time, the elastic modulus is being recorded and plotted as a function of time. The inherent modulus is the shear elastic modulus measured after 60 minutes of curing. [0107] In some embodiments, a crosslinked copolymer can have an entanglement molecular weight (Me) of about 0.003 MPa to about 0.3 MPa. [0108] In some embodiments, a crosslinked copolymer can have a melting temperature (Tm) of about 50°C to about 150°C, such as from about 70°C to about 130°C, such as from about 90°C to about 110°C, alternatively from about 110°C to about 135°C. [0109] In some embodiments, a crosslinked copolymer can have a temperature of crystallization (Tc) of about 10°C to about 150°C, such as from about 30°C to about 100°C, such as from about 60°C to about 80°C, alternatively from about 10°C to about 35°C. The crystallization temperature is measured by DSC, using a cooling rate of 10°C/min. The onset of the crystallization peak defines the Tc value. Impact Copolymer [0110] In one or more embodiments, an impact copolymer (ICP) comprises a continuous phase comprising a thermoplastic polymer, such as polypropylene, and from 10 wt% to 80 wt% of a dispersed phase, based on the total amount of the composition, the dispersed phase including a copolymer of a linear α-olefin, a diene, and optionally C2-C10 α-olefin comonomer different than the C6-C60 linear α-olefin. Impact copolymers can include crosslinked copolymers and/or uncrosslinked copolymers of the present disclosure. [0111] In one or more embodiments, the dispersed phase includes a linear α-olefin, a diene, and ethylene copolymer having greater than or equal to about 60 wt% and less than or equal to about 99.9 wt% C6-C60 linear α-olefin, based on the total weight of the copolymer. In one or more embodiments, the dispersed phase is essentially free of polypropylene. For example, the dispersed phase may include less than 5 wt%, such as less than 1 wt%, such as less than 0.1 wt% polypropylene. [0112] In some embodiments, the impact copolymer composition includes from about 5 wt% to about 80 wt% of a dispersed phase, such as from about 10 wt% to about 50 wt%, such as from about 10 wt% to about 30 wt%, based on the total amount of the composition. In some embodiments, the dispersed phase of the impact copolymer composition, also referred to herein as the rubber phase of the impact copolymer composition, includes a linear α-olefin-diene copolymer. The copolymer can optionally include ethylene. [0113] Properties of an impact copolymer may be influenced by the average particle size or domain size of the dispersed phase, along with the interaction of the dispersed phase with the continuous phase. Utilizing a rubber having high compatibility with polypropylene along with a very low modulus results in impact copolymers and other TPOs with improved properties. The well dispersed rubber domains may provide improved toughening characteristics. In conventional impact copolymers, the average particle size of the dispersed phase is in the range of a few microns. In the impact copolymers of the present disclosure, the rubber domain size may be submicron, e.g. less than about 500 nm. In some embodiments, the rubber domain size is from about 100 nm to 500 nm. Still in other embodiments, the rubber domain size is less than or equal to about 100 nm, such as less than or equal to about 75nm, such as less than or equal to about 50 nm, when determined using AFM. [0114] In at least one embodiment, the impact copolymer can be made in-reactor, in an extruder, or a combination of the two. Continuous Phase – Polypropylene [0115] As noted above, the continuous phase of an impact copolymer of the present disclosure can be one or more polypropylenes. Polypropylenes (also referred to as “propylene- based polymers”) include those solid, typically high-molecular weight plastic resins that primarily include units deriving from the polymerization of propylene. In some embodiments, at least 75%, in other embodiments at least 90%, in other embodiments at least 95%, and in other embodiments at least 97% of the units of the propylene-based polymer are derived from the polymerization of propylene. A polypropylene may be a propylene homopolymer with little or substantially no comonomer content, such as about 5 wt% or less, about 4 wt% or less, about 1 wt% or less, about 0.5 wt% or less, about 0.1 wt% or less, or about 0.05 wt% or less (substantially no comonomer). [0116] In some embodiments, a polypropylene is a propylene homopolymer, such as an isotactic propylene homopolymer. Polypropylene homopolymer can include linear chains and/or chains with long chain branching. [0117] In some embodiments, small amounts (less than 10 wt%) of a comonomer may be used in a polypropylene to obtain desired polymer properties. Typically such copolymers contain less than 10 wt%, or less than 6 wt%, or less than 4 wt%, or less than 2 wt%, or less than 1 wt% of comonomer. In some embodiments, a polypropylene may also include units deriving from the polymerization of ethylene and/or α-olefins such as 1-butene, 1-hexene, 1-octene, 2-methyl-1-propene, 3-methyl-1-pentene, 4-methyl-1-pentene, 5-methyl-1-hexene, and mixtures thereof. Specifically included are the reactor, impact, and random copolymers of propylene with ethylene or the higher α-olefins, described above, or with C10-C20 olefins. [0118] In some embodiments, the polypropylene includes a homopolymer, random copolymer, or impact copolymer polypropylene or combination(s) thereof. In some embodiments, the polypropylene is a high melt strength (HMS) long chain branched (LCB) homopolymer polypropylene. [0119] In some embodiments, a propylene homopolymer or random copolymer is formed using a process utilizing one or two liquid filled loop reactors in series. The term liquid or bulk phase reactor is intended to encompass a liquid propylene process as described by Ser van Ven in “Polypropylene and Other Polyolefins”, 1990, Elsevier Science Publishing Company, Inc., pp. 119-125. The propylene homopolymer or random copolymer may also be prepared in a gas-phase reactor, a series of gas phase reactors or a combination of liquid filled loop reactors and gas phase reactors in any suitable sequence as described in US Pat. No. 7,217,772, incorporated by reference. A polypropylene may be synthesized by using an appropriate polymerization technique such as Ziegler-Natta type polymerizations, and catalysis employing single-site organometallic catalysts including metallocene catalysts. [0120] Propylene based polymer crystallinity and isotacticity and, therefore, the crystallinity and tacticity of a polypropylene can be controlled by the ratio of co-catalyst to electron donor, and the type of co-catalyst/donor system and is also affected by the polymerization temperature. The appropriate ratio of co-catalyst to electron donor is dependent upon the catalyst/donor system selected. [0121] Examples of polypropylene suitable for ICP blends may include ExxonMobil™ PP5341 (available from ExxonMobil); Achieve™ PP6282NE1 (available from ExxonMobil) and/or polypropylene resins with broad molecular weight distribution as described in US 9,453,093 and US 9,464,178; and other polypropylene resins described in US 2018/0016414 and US 2018/0051160; additional examples may include Waymax MFX6 (available from Japan Polypropylene Corp.); Borealis Daploy™ WB140 (available from Borealis AG); Braskem Ampleo 1025MA and Braskem Ampleo 1020GA (available from Braskem Ampleo); and Sabic PP-UMS HEX17112 or Sabic PP571P (available from SABIC). [0122] The amount of hydrogen used to prepare a polypropylene is dependent in large measure on the donor and catalyst system used. Examples of suitable continuous phases include, but are not limited to, homopolymer polypropylene and random ethylene-propylene or random propylene- ^ α-olefin copolymer, where the comonomer includes, but is not limited to, C4, C6 or C8 α-olefins or combinations thereof. Continuous Phase -- Polypropylene Properties [0123] In some embodiments, a polypropylene useful herein includes one or more of the following characteristics: 1) weight average molecular weight (Mw) from about 50,000 g/mol to about 2,000,000 g/mol, such as from about 100,000 g/mol to about 1,000,000 g/mol, from about 100,000 g/mol to about 600,000 g/mol, or from about 400,000 g/mol to about 800,000 g/mol, as measured by gel permeation chromatography (GPC) with polystyrene standards; 2) a number average molecular weight (Mn) from about 25,000 g/mol to about 1,000,000 g/mol, such as from about 50,000 g/mol to about 300,000 g/mol as measured by GPC with polystyrene standards; 3) a Z average molecular weight (Mz) from about 75,000 g/mol to about 3,000,000 g/mol, such as from about 100,000 g/mol to about 2,000,000 g/mol as measured by GPC with polystyrene standards; 4) a broad polydispersity index, Mw/Mn (“PDI”), of about 4.5 or greater, about 5 or greater, about 5.5 or greater, or about 6 or greater. In some embodiments, a polypropylene has a PDI of about 15 or less, about 14 or less, about 13 or less, about 12 or less, about 11 or less, about 10 or less, about 9.5 or less, or about 9 or less. In some embodiments, a polypropylene has a PDI from about 4.5 to about 15, such as from about 4.5 to about 12, from about 5 to about 10, or from about 6 to about 9. In some embodiments, these polydispersity indices are obtained in the absence of visbreaking using peroxide or other post reactor treatment designed to reduce molecular weight; 5) an Mz/Mw ratio of about 2.5 or greater, about 2.6 or greater, about 2.7 or greater, about 2.8 or greater, about 2.9 or greater, about 3 or greater, about 3.1 or greater, or about 3.2 or greater. A polypropylene may have an Mz/Mw ratio of about 7 or less, about 6.5 or less, about 6 or less, about 5.5 or less, or about 5 or less; 6) a melting point (Tm) from about 110°C to about 170°C, such as from about 140°C to about 168°C, or from about 160°C to about 165°C, as determined by ISO 11357-1,2,3; 7) a glass transition temperature (Tg) from about -50°C to about 10°C, such as from about -30°C to about 5°C, or from about -20°C to about 2°C, as determined by ISO 11357-1,2,3; 8) a crystallization temperature (Tc) of about 75 °C or more, such as about 95°C or more, about 100°C or more, about 105°C or more, or from about 105°C to about 130°C), as determined by ISO 11357-1,2,3; 9) a melt flow rate (MFR) from about 0.1 g/10min to about 500 g/10 min, such as from about 0.2 g/10min to about 200 g/10 min, from about 0.5 g/10min to about 175 g/10 min, from about 1 g/10min to about 160 g/10 min, from about 1.5 g/10min to about 150 g/10 min, or from about 3 to about 100 g/10 min. The MFR may be determined by ASTM-1238 measured at load of 2.16 kg and 230°C; 10) a heat of fusion (Hf) of about 52.3 J/g or more, such as about 100 J/g or more, about 125 J/g or more, or about 140 J/g or more; 11) a g'vis of about 1 or less, such as about 0.9 or less, about 0.8 or less, about 0.6 or less, or about 0.5 or less. [0124] In some embodiments, a polypropylene includes a homopolymer of a high- crystallinity isotactic or syndiotactic polypropylene. A polypropylene can have a density of about 0.89 g/cc3 to about 0.91 g/cc3, with the largely isotactic polypropylene having a density of about 0.90 g/cc3 to about 0.91 g/cc3. Also, high and ultra-high molecular weight polypropylene that has a fractional melt flow rate can be employed. In some embodiments, polypropylene resins may be characterized by a MFR (ASTM D-1238; 2.16 kg @ 230°C) that is about 10 g/10min or less, such as about 1 g/10min or less, or about 0.5 g/10min or less. Additives [0125] Impact copolymers of the present disclosure may include one or more additives. The additives may include reinforcing and non-reinforcing fillers, antioxidants, stabilizers, processing oils (or other solvent(s)), compatibilizing agents, lubricants (e.g., oleamide), antiblocking agents, antistatic agents, waxes, coupling agents for the fillers and/or pigment, pigments, flame retardants, antioxidants, or other processing aids, or combination(s) thereof. [0126] It has been discovered that the rubber phase (including a linear α-olefin-diene copolymer) can have less (if any) solvent/oil, as compared to conventional ICPs. For example, an ICP and/or rubber phase thereof can have less than 150 phr solvent/oil, such as less than 125 phr, such as less than 100 phr, such as less than 50 phr, such as less than 25 phr, such as 0 phr. In at least one embodiment, an ICP and/or rubber phase thereof can be substantially (e.g., entirely) free of solvent/oil. In addition, solvent/oil that is optionally present in the rubber phase is less prone to being squeezed out during use. [0127] Impact copolymers of the present disclosure can include additives such that the additives (e.g., fillers of the present disclosure (present in a composition) have an average agglomerate size of less than 50 microns, such as less than 40 microns, such as less than 30 microns, such as less than 20 microns, such as less than 10 microns, such as less than 5 microns, such as less than 1 micron, such as less than 0.5 microns, such as less than 0.1 microns, based on a 1cm x 1cm cross section of the impact copolymer as observed using scanning electron microscopy. [0128] In some embodiments, the impact copolymer may include fillers and coloring agents. Exemplary materials include inorganic fillers such as calcium carbonate, clays, silica, talc, titanium dioxide or carbon black. Any type of carbon black can be used, such as channel blacks, furnace blacks, thermal blacks, acetylene black, lamp black and the like. [0129] In some embodiments, the impact copolymer may include flame retardants, such as calcium carbonate, inorganic clays containing water of hydration such as aluminum trihydroxides (“ATH”) or Magnesium Hydroxide. [0130] In some embodiments, the composition may include UV stabilizers, such as titanium dioxide or Tinuvin® XT-850. The UV stabilizers may be introduced into the roofing composition as part of a master-batch. For example, UV stabilizer may be pre-blended into a master-batch with a thermoplastic resin, such as polypropylene, or a polyethylene, such as linear low density polyethylene. [0131] Still other additives may include antioxidant and/or thermal stabilizers. In an exemplary embodiment, processing and/or field thermal stabilizers may include IRGANOX® B-225 and/or IRGANOX® 1010 available from BASF. [0132] In some embodiments, the impact copolymer may include a polymeric processing additive. The processing additive may be a polymeric resin that has a very high melt flow index. These polymeric resins can include both linear and branched polymers that can have a melt flow rate that is about 500 dg/min or more, such as about 750 dg/min or more, such as about 1000 dg/min or more, such as about 1200 dg/min or more, such as about 1500 dg/min or more. Mixtures of various branched or various linear polymeric processing additives, as well as mixtures of both linear and branched polymeric processing additives, can be employed. Reference to polymeric processing additives can include both linear and branched additives unless otherwise specified. Linear polymeric processing additives can include polypropylene homopolymers, and branched polymeric processing additives can include diene-modified polypropylene polymers. Impact copolymers that include similar processing additives are disclosed in US Pat. No. 6,451,915, which is incorporated herein by reference for purpose of US patent practice. [0133] In some embodiments, the impact copolymer of the present disclosure may optionally include reinforcing and non-reinforcing fillers, antioxidants, stabilizers, rubber processing oil, lubricants, antiblocking agents, anti-static agents, waxes, foaming agents, pigments, flame retardants, nucleating agents, and other processing aids known in the rubber compounding art. These additives can comprise up to about 50 weight percent of the total composition. [0134] Fillers and extenders that can be utilized include conventional inorganics such as calcium carbonate, clays, silica, talc, titanium dioxide, carbon black, a nucleating agent, mica, wood flour, and the like, and blends thereof, as well as inorganic and organic nanoscopic fillers. Molded products [0135] The compositions described herein may be used to prepare molded products in any molding process, including but not limited to, injection molding, gas-assisted injection molding, extrusion blow molding, injection blow molding, injection stretch blow molding, compression molding, rotational molding, foam molding, thermoforming, sheet extrusion, and profile extrusion. [0136] Further, the compositions described herein may be shaped into desirable end use articles by any suitable means. Suitable examples include thermoforming, vacuum forming, blow molding, rotational molding, slush molding, transfer molding, wet lay-up or contact molding, cast molding, cold forming matched-die molding, injection molding, spray techniques, profile co-extrusion, or combinations thereof. [0137] Thermoforming is a process of forming at least one pliable plastic sheet into a desired shape. Typically, an extrudate film of a composition (and any other layers or materials) is placed on a shuttle rack to hold it during heating. The shuttle rack indexes into the oven which pre-heats the film before forming. Once the film is heated, the shuttle rack indexes back to the forming tool. The film is then vacuumed onto the forming tool to hold it in place and the forming tool is closed. The tool stays closed to cool the film and the tool is then opened. The shaped laminate is then removed from the tool. The thermoforming is accomplished by vacuum, positive air pressure, plug-assisted vacuum forming, or combinations and variations of these, once the sheet of material reaches thermoforming temperatures, typically of 140°C to 185°C or higher. A pre-stretched bubble step is used, especially on large parts, to improve material distribution. [0138] Blow molding is another suitable forming means for use with a composition described herein, which includes injection blow molding, multi-layer blow molding, extrusion blow molding, and stretch blow molding, and is especially suitable for substantially closed or hollow objects, such as, for example, gas tanks and other fluid containers. Blow molding is described in more detail in, for example, Concise Encyclopedia of Polymer Science and Engineering, pp.90-92 (Jacqueline I. Kroschwitz, ed., John Wiley & Sons 1990). [0139] Likewise, molded articles may be fabricated by injecting molten polymer into a mold that shapes and solidifies the molten polymer into desirable geometry and thickness of molded articles. Sheets may be made either by extruding a substantially flat profile from a die, onto a chill roll, or by calendaring. Non-woven and Fiber products [0140] The compositions described herein may be used to prepare nonwoven fabrics and fibers in any nonwoven fabric and fiber making process, including but not limited to, melt blowing, spun-bonding, film aperturing, and staple fiber carding. Examples include continuous filament processes, spun-bonding processes, and the like. The spun-bonding process involves the extrusion of fibers through a spinneret. These fibers are then drawn using high velocity air and laid on an endless belt. A calender roll is generally then used to heat the web and bond the fibers to one another although other techniques may be used such as sonic bonding and adhesive bonding. [0141] The copolymer composition according to embodiments disclosed herein are useful in a wide variety of applications where a low elastic modulus, low hysteresis and tensile set is desired. Examples of those applications include automotive overshoot parts (e.g., door handles and skins such as dashboard, instrument panel and interior door skins), house tool handles, airbag covers, toothbrush handles, shoe soles, grips, skins, toys, appliance moldings and fascia, gaskets, furniture moldings and the like. [0142] Other articles of commerce that can be produced include but are not limited by the following examples: awnings and canopies--coated fabric, tents/tarps coated fabric covers, curtains extruded soft sheet, protective cloth coated fabric, bumper fascia, instrument panel and trim skin, coated fabric for auto interior, geo textiles, appliance door gaskets, liners/gaskets/mats, hose and tubing, syringe plunger tips, light weight conveyor belt PVC replacement, modifier for rubber concentrates to reduce viscosity, single ply roofing compositions, recreation and sporting goods, grips for pens, razors, toothbrushes, handles, and the like. Other articles include marine belting, pillow tanks, ducting, dunnage bags, architectural trim and molding, collapsible storage containers, synthetic wine corks, IV and fluid administration bags, examination gloves, and the like. [0143] Exemplary articles made using the compositions described herein include cookware, storage ware, toys, medical devices, sterilizable medical devices, sterilization containers, sheets, crates, containers, packaging, wire and cable jacketing, pipes, geomembranes, sporting equipment, chair mats, tubing, profiles, instrumentation sample holders and sample windows, outdoor furniture, e.g., garden furniture, playground equipment, automotive, boat and water craft components, and other such articles. In particular, the impact copolymers are suitable for automotive components such as bumpers, grills, trim parts, dashboards and instrument panels, exterior door and hood components, spoiler, wind screen, hub caps, mirror housing, body panel, protective side molding, and other interior and external components associated with automobiles, trucks, boats, and other vehicles. The compositions described herein can be useful for producing "soft touch" grips in products such as personal care articles such as toothbrushes, etc.; toys; small appliances; packaging; kitchenware; sport and leisure products; consumer electronics; PVC and silicone rubber replacement medical tubing; industrial hoses; and shower tubing. Processes to Produce ICPs [0144] In some embodiments, a process to produce an impact copolymer composition according to one or more embodiments or combinations of embodiments, includes combining a first component comprising propylene with from 10 wt% to 80 wt% of a second component, based on the total weight of the first and second components, comprising a copolymer of a linear α-olefin and a diene under melt conditions to form a homogenous melt mixture in which the first component and the second component are substantially (e.g., fully) melt miscible; cooling the melt mixture to form the impact copolymer comprising the first component as a continuous phase and the second component as a dispersed phase. [0145] In some embodiments, the process further comprises selecting the continuous phase, and/or the dispersed phase such that the continuous phase and the dispersed phase are melt miscible at the proportions utilized in the resulting impact copolymer. Accordingly, in embodiments, the process includes selecting the continuous phase, e.g., a first component, and selecting the dispersed phase, e.g., a second component, such that a melt blend of the continuous phase with the dispersed phase (e.g., a melt blend of the first and second components) is a homogeneous solution, followed by cooling of the melt to produce the impact copolymer composition. Polymerization Processes [0146] Copolymers of the present disclosure may be produced using processes where monomer (such as linear α-olefin), a diene, and optionally C2-C10 α-olefin comonomer (such as ethylene), are contacted with a catalyst system comprising the result of the combination of an activator, optional support (such as a fluorided support), and a tetrahydroindacene compound, as described herein. The catalyst compound, optional support and activator may be combined in any order, and are combined typically prior to contacting with the monomer. [0147] In some embodiments, 500 ppm or less of diene is added to the polymerization, such as 400 ppm or less, such as or 300 ppm or less. In other embodiments, at least 50 ppm of diene is added to the polymerization, or 100 ppm or more, or 150 ppm or more. [0148] Linear α-olefins (LAOs) can be substituted or unsubstituted C6-C60 LAOs, such as C8-C50 LAOs, such as C10-C40 LAOs, such as C12-C30 LAOs, such as C14-C26 LAOs, such as C16–C26 LAOs, such as C18-C26 LAOs, such as C20-C26 LAOs. LAOs can have some branching. For example, an LAO may have one or more pendant methyl or ethyl substitutions along the LAO backbone. In some embodiments, an LAO is free of branching, e.g. is entirely linear. In at least one embodiment, a linear α-olefin is selected from 1-octene, 1-decene, 1-undecene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene, 1-icosene, 1-henicosene, 1-docosene, 1-tricosene, 1-tetracosene, 1-pentacosene, and combination(s) thereof. [0149] Dienes can be substituted or unsubstituted dienes selected from C4-C60 dienes, such as C5-C50 dienes, such as C5-C40 dienes, such as C5-C30 dienes, such as C5-C20 dienes, such as C6-C15 dienes, such as C6-C10 dienes, such as C7-C9 dienes, such as a substituted or unsubstituted C7 diene, C8 diene, or C9 diene. In at least one embodiment, a diene is a C7 diene. In at least one embodiment, a diene is a substituted or unsubstituted α,Ω-diene (e.g., the diene is a di-vinyl monomer). The dienes can be linear di-vinyl monomers. In at least one embodiment, a diene is selected from butadiene, pentadiene, hexadiene, heptadiene, octadiene, nonadiene, decadiene, undecadiene, dodecadiene, tridecadiene, tetradecadiene, pentadecadiene, hexadecadiene, heptadecadiene, octadecadiene, nonadecadiene, icosadiene, heneicosadiene, docosadiene, tricosadiene, tetracosadiene, pentacosadiene, hexacosadiene, heptacosadiene, octacosadiene, nonacosadiene, triacontadiene, and combination(s) thereof. In some embodiments, a diene is selected from 1,6-heptadiene, 1,7-octadiene, 1,8-nonadiene, 1,9-decadiene, 1,10-undecadiene, 1,11-dodecadiene, 1,12-tridecadiene, 1,13-tetradecadiene, and combination(s) thereof. In at least one embodiment, a diene is selected from cyclopentadiene, vinylnorbornene, norbornadiene, 5-ethylidene-2-norbornene, 5-vinyl-2- norbornene, divinylbenzene, dicyclopentadiene, and combination(s) thereof. In at least one embodiment, a diene is 5-ethylidene-2-norbornene. [0150] In some embodiments, 500 ppm or less of diene is added to the polymerization, such as 400 ppm or less, such as or 300 ppm or less. In other embodiments, at least 50 ppm of diene is added to the polymerization, or 100 ppm or more, or 150 ppm or more. [0151] Polymerization processes of the present disclosure can be carried out in any suitable manner. A suspension, homogeneous, bulk, solution, slurry, or gas phase polymerization process can be used. Such processes can be run in a batch, semi-batch, or continuous mode. Gas phase polymerization processes and slurry processes are preferred. (A homogeneous polymerization process is defined to be a process where at least 90 wt% of the product is soluble in the reaction media.) A bulk homogeneous process is particularly preferred. (A bulk process is defined to be a process where monomer concentration in all feeds to the reactor is 70 vol% or more.) Alternately, no solvent or diluent is present or added in the reaction medium, (except for the small amounts used as the carrier for the catalyst system or other additives, or amounts typically found with the monomer; e.g., propane in propylene). In another embodiment, the process is a slurry process. As used herein the term “slurry polymerization process” means a polymerization process where a supported catalyst is employed and monomers are polymerized on the supported catalyst particles. At least 95 wt% of polymer products derived from the supported catalyst are in granular form as solid particles (not dissolved in the diluent). [0152] Suitable diluents/solvents for polymerization include non-coordinating, inert liquids. Examples include straight and branched-chain hydrocarbons, such as isobutane, butane, pentane, isopentane, hexanes, isohexane, heptane, octane, dodecane, and mixtures thereof; cyclic and alicyclic hydrocarbons, such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof, such as can be found commercially (Isopar™); perhalogenated hydrocarbons, such as perfluorinated C4-10 alkanes, chlorobenzene, and aromatic and alkylsubstituted aromatic compounds, such as benzene, toluene, mesitylene, and xylene. Suitable solvents also include liquid olefins which may act as monomers or comonomers including ethylene, propylene, 1-butene, 1-hexene, 1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-octene, 1-decene, and mixtures thereof. In at least one embodiment, aliphatic hydrocarbon solvents are used as the solvent, such as isobutane, butane, pentane, isopentane, hexanes, isohexane, heptane, octane, dodecane, and mixtures thereof; cyclic and alicyclic hydrocarbons, such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof. In another embodiment, the solvent is not aromatic, such as aromatics are present in the solvent at less than 1 wt%, such as less than 0.5 wt%, such as less than 0 wt% based upon the weight of the solvents. [0153] In at least one embodiment, the feed concentration of the monomers and comonomers for the polymerization is 60 vol% solvent or less, such as 40 vol% or less, or such as 20 vol% or less, based on the total volume of the feedstream. In at least one embodiment, the polymerization is run in a bulk process. [0154] Polymerizations can be run at any temperature and/or pressure suitable to obtain the desired polymers. Typical temperatures and/or pressures include a temperature from about 0°C to about 300°C, such as about 20°C to about 200°C, such as about 35°C to about 150°C, such as from about 40°C to about 120°C, such as from about 45°C to about 80°C; and at a pressure from about 0.35 MPa to about 16 MPa, such as from about 0.45 MPa to about 13 MPa, such as from about 0.5 MPa to about 12 MPa. [0155] In a typical polymerization, the run time of the reaction is up to 300 minutes, such as from about 5 to 250 minutes, such as from about 10 to 120 minutes. [0156] In some embodiments, hydrogen is present in the polymerization reactor at a partial pressure of 0.001 to 50 psig (0.007 to 345 kPa), such as from 0.01 to 25 psig (0.07 to 172 kPa), such as 0.1 to 10 psig (0.7 to 70 kPa). [0157] In at least one embodiment, the activity of the catalyst is at least 800 gpolymer/gsupported catalyst/hour, such as 1,000 or more gpolymer/gsupported catalyst/hour, such as 100 or more gpolymer/gsupported catalyst/hour, such as 1,600 or more gpolymer/gsupported catalyst/hour. [0158] In at least one embodiment, little or no scavenger is used in the process to produce the copolymer. For example, scavenger (such as tri alkyl aluminum) is present at zero mol%, alternately the scavenger is present at a molar ratio of scavenger metal to transition metal of less than 100:1, such as less than 50:1, such as less than 15:1, such as less than 10:1. [0159] In at least one embodiment, the polymerization: 1) is conducted at temperatures of 0°C to 300°C (such as 25°C to 150°C, such as 40°C to 120°C, such as 45°C to 80°C); 2) is conducted at a pressure of atmospheric pressure to 16 MPa (such as 0.35 to 14 MPa, such as from 0.45 to 12 MPa, such as from 0.5 to 6 MPa); 3) is conducted in an aliphatic hydrocarbon solvent (such as isobutane, butane, pentane, isopentane, hexanes, isohexane, heptane, octane, dodecane, and mixtures thereof; cyclic and alicyclic hydrocarbons, such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof; such as where aromatics are present in the solvent at less than 1 wt%, such as, less than 0.5 wt%, such as at 0 wt% based upon the weight of the solvents); 4) the polymerization can occur in one reaction zone; and 5) optionally, hydrogen is present in the polymerization reactor at a partial pressure of 0.001 to 50 psig (0.007 to 345 kPa) (such as from 0.01 to 25 psig (0.07 to 172 kPa), such as 0.1 to 10 psig (0.7 to 70 kPa)). [0160] A “reaction zone” also referred to as a “polymerization zone” is a vessel where polymerization takes place, for example a batch reactor. When multiple reactors are used in either series or parallel configuration, each reactor is considered as a separate polymerization zone. For a multi-stage polymerization in both a batch reactor and a continuous reactor, each polymerization stage is considered as a separate polymerization zone. In at least one embodiment, the polymerization occurs in one reaction zone. Gas phase polymerization [0161] Generally, in a fluidized gas bed process used for producing polymers, a gaseous stream containing one or more monomers is continuously cycled through a fluidized bed in the presence of a catalyst under reactive conditions. The gaseous stream is withdrawn from the fluidized bed and recycled back into the reactor. Simultaneously, polymer product is withdrawn from the reactor and fresh monomer is added to replace the polymerized monomer. (See for example US 4,543,399; US 4,588,790; US 5,028,670; US 5,317,036; US 5,352,749; US 5,405,922; US 5,436,304; US 5,453,471; US 5,462,999; US 5,616,661; and US 5,668,228 all of which are incorporated herein by reference.) Slurry phase polymerization [0162] A slurry polymerization process generally operates between 1 to about 50 atmosphere pressure range (15 psi to 735 psi, 103 kPa to 5,068 kPa) or even greater and temperatures in the range of 0 °C to about 120 °C. In a slurry polymerization, a suspension of solid, particulate polymer is formed in a liquid polymerization diluent medium to which monomer and comonomers along with catalyst are added. The suspension including diluent is intermittently or continuously removed from the reactor where the volatile components are separated from the polymer and recycled, optionally after a distillation, to the reactor. The liquid diluent employed in the polymerization medium is typically an alkane having from 3 to 7 carbon atoms, such as a branched alkane. The medium employed should be liquid under the conditions of polymerization and relatively inert. When a propane medium is used the process must be operated above the reaction diluent critical temperature and pressure. Preferably, a hexane or an isobutane medium is employed. [0163] In an embodiment, a polymerization technique herein is referred to as a particle form polymerization, or a slurry process where the temperature is kept below the temperature at which the polymer goes into solution. Such technique is described in for instance US 3,248,179 incorporated herein by reference. The temperature in the particle form process may be from about 85°C to about 110°C. Two example polymerization methods for the slurry process are those employing a loop reactor and those utilizing a plurality of stirred reactors in series, parallel, or combinations thereof. Non-limiting examples of slurry processes include continuous loop or stirred tank processes. Also, other examples of slurry processes are described in US 4,613,484, which is herein fully incorporated by reference. [0164] In another embodiment, the slurry process is carried out continuously in a loop reactor. The catalyst, as a slurry in isobutane or as a dry free flowing powder, is injected regularly to the reactor loop, which is itself filled with circulating slurry of growing polymer particles in a diluent of isobutane containing monomer and comonomer. Hydrogen, optionally, may be added as a molecular weight control. (In one embodiment 500 ppm or less of hydrogen is added, or 400 ppm or less or 300 ppm or less. In other embodiments at least 50 ppm of hydrogen is added, or 100 ppm or more, or 150 ppm or more.) [0165] The reactor may be maintained at a pressure of 3,620 kPa to 4,309 kPa and at a temperature in the range of about 60°C to about 104°C depending on the desired polymer melting characteristics. Reaction heat is removed through the loop wall since much of the reactor is in the form of a double-jacketed pipe. The slurry is allowed to exit the reactor at regular intervals or continuously to a heated low pressure flash vessel, rotary dryer and a nitrogen purge column in sequence for removal of the isobutane diluent and all unreacted monomer and comonomers. The resulting hydrocarbon free powder is then compounded for use in various applications. [0166] Other additives may also be used in the polymerization, as desired, such as one or more scavengers, promoters, modifiers, chain transfer agents (such as diethyl zinc), reducing agents, oxidizing agents, hydrogen, aluminum alkyls, or silanes. [0167] Useful chain transfer agents are typically alkylalumoxanes, a compound represented by the formula AlR3, ZnR2 (where each R is, independently, a C1-C8 aliphatic radical, such as methyl, ethyl, propyl, butyl, penyl, hexyl octyl or an isomer thereof) or a combination thereof, such as diethyl zinc, methylalumoxane, trimethylaluminum, triisobutylaluminum, trioctylaluminum, or a combination thereof. Polymerization Catalysts [0168] Polymerization catalysts of the present disclosure for forming linear α-olefin-diene copolymers described herein can be monocyclopentadienyl group 4 transition metal compounds represented by the formula: TyCp'mMGnXq wherein Cp' is a tetrahydroindacenyl group (such as tetrahydro-s-indacenyl or tetrahydro-as- indacenyl) which may be substituted or unsubstituted (optionally provided that when Cp' is tetrahydro-s-indecenyl: 1) the 3 and/or 4 positions are not aryl or substituted aryl, 2) the 3 position is not directly bonded to a group 15 or 16 heteroatom, 3) there are no additional rings fused to the tetrahydroindacenyl ligand, 4) T is not bonded to the 2-position, 5) the 5, 6, or 7- position (such as the 6 position) is geminally disubstituted, such as with two C1-C10 alkyl groups; and/or 6) when G is t-butylamido, adamantylamido, cyclooctylamido, cyclohexylamido or cyclododecylamido and the 5 and 7 positions are H, then the 6 position and/or X is not methyl); M is a group 3, 4, 5, or 6 transition metal, such as group 4 transition metal, for example titanium, zirconium, or hafnium (such as titanium); G is a heteroatom group represented by the formula JRiz where J is N, P, O or S, Ri is a hydrocarbyl group, such as a C1 to C20 hydrocarbyl group, and z is 1 or 2 (preferably J is N and z is 1); T is a bridging group (such as dialkylsilylene or dialkylcarbylene), T can be (CR8R9)x, SiR8R9 or GeR8R9 where x is 1 or 2, R8 and R9 are independently selected from substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl and germylcarbyl and R8 and R9 may optionally be bonded together to form a ring structure, and in a particular embodiment, R8 and R9 are not aryl); y is 0 or 1, indicating the absence or presence of T; X is a leaving group (such as a halide, a hydride, an alkyl group, an alkenyl group or an arylalkyl group); m = 1; n = 1, 2 or 3; q = 1, 2 or 3; and the sum of m+n+q is equal to the oxidation state of the transition metal (such as 3, 4, 5, or 6, such as 4); such as m = 1, n = 1, q is 2, and y = 1. [0169] This invention also relates to a catalyst system comprising an activator and at least one metallocene catalyst compound, where the metallocene is a tetrahydroindacenyl group 4 transition metal compound, such as represented by the formula: TyCp'mMGnXq wherein Cp' is a tetrahydroindacenyl group (such as tetrahydro-s-indacenyl or tetrahydro-as- indacenyl) which may be substituted or unsubstituted (optionally provided that when Cp' is tetrahydro-s-indecenyl: 1) the 3 and/or 4 positions are not aryl or substituted aryl, 2) the 3 position is not directly bonded to a group 15 or 16 heteroatom, 3) there are no additional rings fused to the tetrahydroindacenyl ligand, 4) T is not bonded to the 2-position, and/or 5) the 5, 6, or 7-position (such as the 6 position) is geminally disubstituted, such as with two C1-C10 alkyl groups, and optionally and/or 6) when G is t-butylamido, adamantylamido, cyclooctylamido, cyclohexylamido or cyclododecylamido and the 5 and 7 positions are H, then the 6 position and/or X is not methyl); M is a group 3, 4, 5, or 6 transition metal, preferrably group 4 transition metal, for example titanium, zirconium, or hafnium (such as titanium); G is a heteroatom group represented by the formula JRi z where J is N, P, O or S, Ri is a hydrocarbyl group, such as a C1 to C20 hydrocarbyl group (alternately a C2 to C20 hydrocarbyl group), and z 1 or 2, (preferably J is N and z is 1); T is a bridging group (such as dialkylsilylene or dialkylcarbylene), T is preferably (CR8R9)x, SiR8R9 or GeR8R9 where x is 1 or 2, R8 and R9 are independently selected from substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl and germylcarbyl and R8 and R9 may optionally be bonded together to form a ring structure, and in a particular embodiment, R8 and R9 are not aryl); y is 0 or 1, indicating the absence or presence of T; X is a leaving group (such as a halide, a hydride, an alkyl group, an alkenyl group or an arylalkyl group); m = 1; n = 1, 2 or 3; q = 1, 2, or 3; and the sum of m + n + q is equal to the oxidation state of the transition metal (such as 3, 4, 5, or 6, such as 4); such as m = 1, n = 1, q is 2, and y = 1. [0170] In some embodiments, the 6 position is not methyl. [0171] In at least one embodiment, each Ri is a linear, branched or cyclic C1 to C20 hydrocarbyl group, such as independently selected from the group consisting of methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, and isomers thereof, such as t-butyl, cyclooctyl, cyclohexyl, cyclodecyl, cyclododecyl, and or adamantyl. [0172] In at least one embodiment, a mono-tetrahydro-s-indacenyl group 4 transition metal compound is represented by the Formula (I) or (II): ) or
Figure imgf000039_0001
I) where M is a group 4 metal (such as Hf,Ti or Zr, such as Ti);
Figure imgf000039_0002
J is N, O, S or P (such as N); p is 1 or 2; each Ra is independently C1-C10 alkyl (alternately a C2-C10 alkyl); each Rc is independently hydrogen or a C1-C10 alkyl; each R2, R3, R4, and R7 is independently hydrogen, or a C1-C50 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germylcarbyl, (preferably provided that: 1) R3 and/or R4 are not aryl or substituted aryl, 2) R3 is not directly bonded to a group 15 or 16 heteroatom, and/or 3) adjacent R4, Rc, Ra or R7 do not join together to form a fused ring system); each R' is, independently, a C1-C100 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germylcarbyl; T is a bridging group, such as (CR8R9)x, SiR8R9 or GeR8R9 where x is 1 or 2, R8 and R9 are independently selected from substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl and germylcarbyl and R8 and R9 may optionally be bonded together to form a ring structure; each X is, independently, a leaving group, or two Xs are joined and bound to the metal atom to form a metallocycle ring, or two Xs are joined to form a chelating ligand, a diene ligand, or an alkylidene. Preferably, in Formula (I), when J(R')p is t-butylamido, adamantylamido, cyclooctylamido, cyclohexylamido or cyclododecylamido and Rc are H, then Ra and or X is not methyl; and/or preferably, in Formula (II), when JR' is t-butylamido, adamantylamido, cyclooctylamido, cyclohexylamido or cyclododecylamido and Rc is H, then Ra and/or X is not methyl. [0173] Optionally, Ra is not methyl. [0174] In at least one embodiment, a bridged mono-tetrahydro-as-indacenyl transition metal compound is represented by the Formula (III) or (IV): where M is group 3, 4, 5,or 6 transition metal(preferably M is a group 4 metal (such
Figure imgf000040_0001
as Hf, Ti or Zr, such as Ti); B is the oxidation state of M, and is 3, 4, 5 or 6; c is B-2; J is N, O, S or P; p is 1 or 2; each R2, R3, R6, and R7, is independently hydrogen, or a C1-C50 substituted or unsubstituted hydrocarbyl, halocarbyl or silylcarbyl; each Rb and Rc is independently C1-C10 alkyl, or hydrogen; each R' is, independently, a C1-C100 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germycarbyl; T is a bridging group, such as (CR8R9)x, SiR8R9 or GeR8R9 where x is 1 or 2, R8 and R9 are independently selected from hydrogen, substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl and germylcarbyl, and R8 and R9 may optionally be bonded together to form a ring structure; y is 1 when T is present and y is 0 when T is absent; and each X is, independently, a leaving group, or two Xs are joined and bound to the metal atom to form a metallocycle ring, or two Xs are joined to form a chelating ligand, a diene ligand, or an alkylidene. [0175] In at least one embodiment, a bridged mono-tetrahydro-as-indacenyl transition metal compound is represented by the Formula (A) or (B): ) ) where M, B, c, J, p, R2, R3
Figure imgf000041_0001
, R6, R7, R', T, y and X are as defined above for Formula (III) and (IV) and each Rb, Rc, and Rd is independently C1-C10 alkyl, or hydrogen, preferably provided that both Rb, both Rc, or both Rd are not hydrogen. In some embodiments, Rd is independently selected from the group consisting of hydrogen, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and isomers thereof, such as hydrogen or methyl. [0176] The present disclosure also relates to bridged monoindacenyl group 4 transition metal compounds represented by the Formula (V) or (VI):
Figure imgf000042_0001
where M* is a group 4 transition metal (such as Hf, Zr or Ti); J is N, O, S or P (preferably J is N and p is 1); p is 1 or 2, each R2, R3, R6, and R7 is independently hydrogen, or a C1-C50 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germycarbyl; each Rb and each Rc is independently a C1-C10 alkyl or hydrogen; each R' is, independently, a C1-C100 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germylcarbyl; T is a bridging group, such as (CR8R9)x, SiR8R9 or GeR8R9 where x is 1 or 2, R8 and R9 are independently selected from substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl and germylcarbyl and R8 and R9 may optionally be bonded together to form a ring structure; y is 1 when T is present and y is 0 when T is absent; and each X is, independently, a leaving group, or two Xs are joined and bound to the metal atom to form a metallocycle ring, or two Xs are joined to form a chelating ligand, a diene ligand, or an alkylidene. [0177] In a particularly useful embodiment of Formula (V) and/or (VI), M* is a group 4 metal (such as Hf, Zr or Ti); J is nitrogen; each R2, R3, R6, and R7 is independently hydrogen, or a C1-C20 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germycarbyl; each Rb and each Rc is independently C1-C10 alkyl (such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, or an isomer thereof), or hydrogen; R' is a C1-C20 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germylcarbyl; T is (CR8R9)x, SiR8R9 or GeR8R9 where x is 1 or 2, R8 and R9 are independently selected from substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl and germylcarbyl, y is 1, and R8 and R9 may optionally be bonded together to form a ring structure; each X is halogen or a C1 to C20 hydrocarbyl wherein the hydrocarbyls are optionally joined to form a chelating ligand, a diene, or an alkylidene. [0178] In at least one embodiment, M and/or M* are a group 4 metal, such as titanium. [0179] In at least one embodiment, R3 is not substituted with a group 15 or 16 heteroatom. [0180] In at least one embodiment, each R2, R3, R4, R6, and R7 is independently hydrogen, or a C1-C50 substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl or germylcarbyl, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, and dodecyl or an isomer thereof. [0181] In at least one embodiment, each Ra is independently selected from the group consisting of methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and isomers thereof, such as methyl and ethyl, such as methyl. [0182] Alternately, in any of the above formulas, the indacene ligand does not have a methyl at the 6 position, alternately one or both Ra are not methyl. [0183] In at least one embodiment, Rb is independently selected from the group consisting of hydrogen, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and isomers thereof, such as methyl and ethyl, such as methyl. [0184] In at least one embodiment, Rc is independently selected from the group consisting of hydrogen, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and isomers thereof, such as hydrogen or methyl. [0185] In at least one embodiment, R' is a C1-C100 substituted or unsubstituted hydrocarbyl, halocarbyl, or silylcarbyl, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl or an isomer thereof, such as t-butyl, neopentyl, cyclohexyl, cyclooctyl, cyclododecyl, adamantyl, or norbornyl. [0186] In any embodiment of the invention, T is a bridging group containing at least one Group 13, 14, 15, or 16 element, in particular boron or a Group 14, 15, or 16 element. Examples of suitable bridging groups include P(=S)R*, P(=Se)R*, P(=O)R*, R*2C, R*2Si, R*2Ge, R*2CCR*2, R*2CCR*2CR*2, R*2CCR*2CR*2CR*2, R*C=CR*, R*C=CR*CR*2, R*2CCR*=CR*CR*2, R*C=CR*CR*=CR*, R*C=CR*CR*2CR*2, R*2CSiR*2, R*2SiSiR*2, 2*2SiOSiR*2, R*2CSiR*2CR*2, R*2SiCR*2SiR*2, R*C=CR*SiR*2, R*2CGeR*2, R*2GeGeR*2, R*2CGeR*2CR*2, R*2GeCR*2GeR*2, R*2SiGeR*2, R*C=CR*GeR*2, R*B, R*2C–BR*, R*2C–BR*–CR*2, R*2C–O–CR*2, R*2CR*2C–O–CR*2CR*2, R*2C–O– CR*2CR*2, R*2C–O–CR*=CR*, R*2C–S–CR*2, R*2CR*2C–S–CR*2CR*2, R*2C–S– CR*2CR*2, R*2C–S–CR*=CR*, R*2C–Se–CR*2, R*2CR*2C–Se–CR*2CR*2, R*2C–Se– CR*2CR*2, R*2C–Se–CR*=CR*, R*2C–N=CR*, R*2C–NR*–CR*2, R*2C–NR*–CR*2CR*2, R*2C–NR*–CR*=CR*, R*2CR*2C–NR*–CR*2CR*2, R*2C–P=CR*, R*2C–PR*–CR*2, O, S, Se, Te, NR*, PR*, AsR*, SbR*, O-O, S-S, R*N-NR*, R*P-PR*, O-S, O-NR*, O-PR*, S-NR*, S-PR*, and R*N-PR* where R* is hydrogen or a C1-C20 containing hydrocarbyl, substituted hydrocarbyl, halocarbyl, substituted halocarbyl, silylcarbyl or germylcarbyl substituent and optionally two or more adjacent R* may join to form a substituted or unsubstituted, saturated, partially unsaturated or aromatic, cyclic or polycyclic substituent. Preferred examples for the bridging group T include CH2, CH2CH2, SiMe2, SiPh2, SiMePh, Si(CH2)3, Si(CH2)4, O, S, NPh, PPh, NMe, PMe, NEt, NPr, NBu, PEt, PPr, Me2SiOSiMe2, and PBu. In a preferred embodiment of the invention in any embodiment of any formula described herein, T is represented by the formula ERd 2 or (ERd 2)2, where E is C, Si, or Ge, and each Rd is, independently, hydrogen, halogen, C1 to C20 hydrocarbyl (such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, or dodecyl) or a C1 to C20 substituted hydrocarbyl, and two Rd can form a cyclic structure including aromatic, partially saturated, or saturated cyclic or fused ring system. Preferably, T is a bridging group comprising carbon or silica, such as dialkylsilyl, preferably T is selected from CH2, CH2CH2, C(CH3)2, SiMe2, Me2Si-SiMe2, cyclotrimethylenesilylene (Si(CH2)3), cyclopentamethylenesilylene (Si(CH2)5) and cyclotetramethylenesilylene (Si(CH2)4). [0187] In at least one embodiment, T is CR8R9, R8R9C-CR8R9, SiR8R9 or GeR8*R9* where R8 and R9 are independently selected from substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl and R8 and R9 may optionally be bonded together to form a ring structure, such as each R8 and R9 is independently methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, benzyl, phenyl, methylphenyl or an isomer thereof, such as methyl, ethyl, propyl, butyl, or hexyl. [0188] In at least one embodiment, at least one of R8 or R9 is not aryl. In at least one embodiment, R8 is not aryl. In at least one embodiment, R9 is not aryl. In at least one embodiment, R8 and R9 are not aryl. [0189] In at least one embodiment, R8 and R9 are independently C1-C10 alkyls, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, or an isomer thereof. [0190] In at least one embodiment, each R2, R3, R4, and R7 is independently hydrogen or hydrocarbyl. In at least one embodiment, each R2, R3, R6, and R7 is independently hydrogen or hydrocarbyl. [0191] In at least one embodiment, each R2, R3, R4, and R7 is independently hydrogen or a C1-C10 alkyl, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, or an isomer thereof. [0192] In at least one embodiment, each R2, R3, R6, and R7 is independently hydrogen or a C1-C10 alkyl, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, or an isomer thereof. [0193] In at least one embodiment, R2 is a C1-C10 alkyl and R3, R4, and R6 are hydrogen. In some embodiments, R2 is a C1-C10 alkyl and R3, R6, and R7 are hydrogen. [0194] In at least one embodiment, R2, R3, R4, and R6 are hydrogen. In some embodiments, R2, R3, R6, and R7 are hydrogen. [0195] In at least one embodiment, R2 is methyl, ethyl, or an isomer of propyl, butyl, pentyl or hexyl, and R3, R4, and R7 are hydrogen. In at least one embodiment, R2 is methyl, ethyl, or an isomer of propyl, butyl, pentyl or hexyl, and R3, R6, and R7 are hydrogen. [0196] In at least one embodiment, R2 is methyl and R3, R4, and R7 are hydrogen. In some embodiments, R2 is methyl and R3, R6, and R7 are hydrogen. [0197] In at least one embodiment, R3 is hydrogen. In at least one embodiment, R2 is hydrogen. In at least one embodiment, R' is C1-C100 or C1-C30 substituted or unsubstituted hydrocarbyl. [0198] In at least one embodiment, R' is C1-C30 substituted or unsubstituted alkyl (linear, branched, or cyclic), aryl, alkaryl, or heterocyclic group. [0199] In at least one embodiment, R' is C1-C30 linear, branched or cyclic alkyl group. In at least one embodiment, R' is methyl, ethyl, or any isomer of propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, or dodecyl. [0200] In at least one embodiment, R' is a cyclic or polycyclic hydrocarbyl. In at least one embodiment, R' is selected from tert-butyl, neopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, cycloundecyl, cyclododecyl, adamantyl, and norbornyl. [0201] In at least one embodiment, Ri is selected from tert-butyl, neopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, cycloundecyl, cyclododecyl, adamantyl, and norbornyl. [0202] In at least one embodiment, T is selected from diphenylmethylene, dimethylmethylene, 1,2-ethylene, cyclotrimethylenesilylene, cyclotetramethylenesilylene, cyclopentamethylenesilylene, dimethylsilylene, diethylsilylene, methylethylsilylene, and dipropylsilylene. [0203] In at least one embodiment, each Ra is independently methyl, ethyl, propyl, butyl, pentyl or hexyl. [0204] In at least one embodiment, each Ra is independently methyl or ethyl. In at least one embodiment, each Ra is methyl. [0205] In at least one embodiment, each Rb is independently hydrogen, methyl, ethyl, propyl, butyl, pentyl or hexyl. In at least one embodiment, each Rb and each Rc is independently hydrogen, methyl, ethyl, propyl, butyl, pentyl or hexyl. In at least one embodiment, each Rb is independently hydrogen, methyl or ethyl. In at least one embodiment, each Rb is methyl. [0206] In at least one embodiment, each X is hydrocarbyl, halocarbyl, or substituted hydrocarbyl or halocarbyl. In at least one embodiment, X is methyl, benzyl, or halo where halo includes fluoro, chloro, bromo and iodido. [0207] In at least one embodiment of Formula (I) or (II) described herein: 1) R3 and/or R4 are not aryl or substituted aryl, 2) R3 is not directly bonded to a group 15 or 16 heteroatom, and 3) adjacent R4, Rc, Ra or R7 do not join together to form a fused ring system, and 4) each Ra is a C1 to C10 alkyl (such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, or an isomer thereof). [0208] Useful catalysts also include compounds represented by the Formula (VII): TyCp'mMGnXq wherein Cp' is a tetrahydroindacenyl group (such as tetrahydro-s-indacenyl or tetrahydro-as- indacenyl) which may be substituted or unsubstituted, provided that when Cp' is tetrahydro-s- indecenyl: 1) the 3 and/or 4 positions are not aryl or substituted aryl, 2) the 3 position is not directly bonded to a group 15 or 16 heteroatom, 3) there are no additional rings fused to the tetrahydroindacenyl ligand, 4) T is not bonded to the 2-position, and 5) the 5, 6, or 7-position (such as the 6 position) is geminally disubstituted, such as with two C1-C10 alkyl groups; M is a group 3, 4, 5, or 6 transition metal, preferably group 4 transition metal, for example titanium, zirconium, or hafnium (such as titanium); G is a heteroatom group represented by the formula JRiz where J is N, P, O or S, Ri is a C1 to C20 hydrocarbyl group, and z is 1 or 2 (preferably J is N and z is 1); T is a bridging group (such as dialkylsilylene or dialkylcarbylene); T is preferably (CR8R9)x, SiR8R9 or GeR8R9 where x is 1 or 2, R8 and R9 are independently selected from substituted or unsubstituted hydrocarbyl, halocarbyl, silylcarbyl and germylcarbyl and R8 and R9 may optionally be bonded together to form a ring structure, and in a particular embodiment, R8 and R9 are not aryl); y is 0 or 1, indicating the absence or presence of T; X is a leaving group (such as a halide, a hydride, an alkyl group, an alkenyl group or an arylalkyl group); m = 1; n = 1, 2 or 3; q = 1, 2 or 3; and the sum of m + n + q is equal to the oxidation state of the transition metal (such as 3, 4, 5, or 6, such as 4); such as m = 1, n = 1, q is 2, and y = 1. [0209] In at least one embodiment of Formula (VII) described herein, M is a Group 4 transition metal (such as Hf, Ti and/or Zr, such as Ti). [0210] In at least one embodiment of Formula (VII) described herein, J is N, and Ri is a linear branched or cyclic hydrocarbyl group having from one to twenty carbon atoms (such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, or an isomer thereof, including t-butyl, cyclododecyl, cyclooctyl or an isomer thereof) and z is 1 or 2, such as 1, and JRiz is cyclododecyl amido, t-butyl amido, and or 1-adamantyl amido. [0211] In at least one embodiment of Formula (VII) described herein, each X may be, independently, a halide, a hydride, an alkyl group, an alkenyl group or an arylalkyl group. [0212] Alternately, in at least one embodiment of Formula (VII), each X is, independently, selected from the group consisting of hydrocarbyl radicals having from 1 to 20 carbon atoms, aryls, hydrides, amides, alkoxides, sulfides, phosphides, halides, dienes, amines, phosphines, ethers, and a combination thereof, (two X’s may form a part of a fused ring or a ring system), such as each X is independently selected from halides, aryls and C1 to C5 alkyl groups, such as each X is a phenyl, methyl, ethyl, propyl, butyl, pentyl, or chloro group. [0213] In at least one embodiment of Formula (VII) described herein, the Cp' group may be substituted with a combination of substituent groups R. Non-limiting examples of substituent groups R include one or more from the group selected from hydrogen, or linear, branched alkyl radicals, or alkenyl radicals, alkynyl radicals, cycloalkyl radicals or aryl radicals, acyl radicals, alkoxy radicals, aryloxy radicals, alkylthio radicals, dialkylamino radicals, alkoxycarbonyl radicals, aryloxycarbonyl radicals, carbamoyl radicals, alkyl- or dialkyl- carbamoyl radicals, acyloxy radicals, acylamino radicals, aroylamino radicals, straight, branched or cyclic, alkylene radicals, or combination thereof. In an embodiment, substituent groups R have up to 50 non-hydrogen atoms, such as from 1 to 30 carbon, that can also be substituted with halogens or heteroatoms or the like, provided that when Cp' is tetrahydro-s- indecenyl: 1) the 3 and/or 4 position is not aryl or substituted aryl, 2) the 3-position is not substituted with a group 15 or 16 heteroatom, 3) there are no additional rings fused to the tetrahydroindacenyl ligand, 4) T is not bonded to the 2-position, and 5) the 5, 6, or 7-position (such as the 6 position) is geminally disubstituted, such as with two C1-C10 alkyl groups. Non- limiting examples of alkyl substituents R include methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, benzyl or phenyl groups and the like, including all their isomers, for example, tertiary butyl, isopropyl and the like. Other hydrocarbyl radicals include fluoromethyl, fluoroethyl, difluoroethyl, iodopropyl, bromohexyl chlorobenzyl and hydrocarbyl substituted organometalloid radicals including trimethylsilyl, trimethylgermyl, methyldiethylsilyl and the like; and halocarbyl-substituted organometalloid radicals including tris(trifluoromethyl)-silyl, methylbis(difluoromethyl)silyl, bromomethyldimethylgermyl and the like; and disubstituted boron radicals including dimethylboron for example; and disubstituted pnictogen radicals including dimethylamine, dimethylphosphine, diphenylamine, methylphenylphosphine, chalcogen radicals including methoxy, ethoxy, propoxy, phenoxy, methylsulfide and ethylsulfide. Non-hydrogen substituents R include the atoms carbon, silicon, boron, aluminum, nitrogen, phosphorus, oxygen, tin, sulfur, germanium and the like, including olefins such as, but not limited to, olefinically unsaturated substituents including vinyl-terminated ligands, for example but-3-enyl, prop-2-enyl, hex-5-enyl and the like. [0214] In at least one embodiment of Formula (VII) described herein, the Cp' group, the substituent(s) R are, independently, hydrocarbyl groups, heteroatoms, or heteroatom containing groups, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl or an isomer thereof, N, O, S, P, or a C1 to C20 hydrocarbyl substituted with an N, O, S and or P heteroatom or heteroatom containing group (typically having up to 12 atoms, including the N, O, S and P heteroatoms), provided that when Cp' is tetrahydro-s- indecenyl, the 3 and/or 4 position are not aryl or substituted aryl, the 3 position is not substituted with a group 15 or 16 heteroatom, and there are no additional rings fused to the tetrahydroindacenyl ligand, T is not bonded to the 2-position, and the 5, 6, or 7-position (such as the 6 position) is geminally disubstituted, such as with two C1-C10 alkyl groups. [0215] In at least one embodiment of Formula (VII), the Cp' group is tetrahydro-as- indecenyl which may be substituted. [0216] In at least one embodiment of Formula (VII), y is 1 and T is a bridging group containing at least one Group 13, 14, 15, or 16 element, in particular boron or a Group 14, 15 or 16 element. Examples of suitable bridging groups include P(=S)R*, P(=Se)R*, P(=O)R*, R*2C, R*2Si, R*2Ge, R*2CCR*2, R*2CCR*2CR*2, R*2CCR*2CR*2CR*2, R*C=CR*, R*C=CR*CR*2, R*2CCR*=CR*CR*2, R*C=CR*CR*=CR*, R*C=CR*CR*2CR*2, R*2CSiR*2, R*2SiSiR*2, R*2SiOSiR*2, R*2CSiR*2CR*2, R*2SiCR*2SiR*2, R*C=CR*SiR*2, R*2CGeR*2, R*2GeGeR*2, R*2CGeR*2CR*2, R*2GeCR*2GeR*2, R*2SiGeR*2, R*C=CR*GeR*2, R*B, R*2C–BR*, R*2C–BR*–CR*2, R*2C–O–CR*2, R*2CR*2C–O– CR*2CR*2, R*2C–O–CR*2CR*2, R*2C–O–CR*=CR*, R*2C–S–CR*2, R*2CR*2C–S– CR*2CR*2, R*2C–S–CR*2CR*2, R*2C–S–CR*=CR*, R*2C–Se–CR*2, R*2CR*2C–Se– CR*2CR*2, R*2C–Se–CR*2CR*2, R*2C–Se–CR*=CR*, R*2C–N=CR*, R*2C–NR*–CR*2, R*2C–NR*–CR*2CR*2, R*2C–NR*–CR*=CR*, R*2CR*2C–NR*–CR*2CR*2, R*2C–P=CR*, R*2C–PR*–CR*2, O, S, Se, Te, NR*, PR*, AsR*, SbR*, O-O, S-S, R*N-NR*, R*P-PR*, O-S, O-NR*, O-PR*, S-NR*, S-PR*, and R*N-PR* where R* is hydrogen or a C1-C20 containing hydrocarbyl, substituted hydrocarbyl, halocarbyl, substituted halocarbyl, silylcarbyl or germylcarbyl substituent and optionally two or more adjacent R* may join to form a substituted or unsubstituted, saturated, partially unsaturated or aromatic, cyclic or polycyclic substituent. Examples for the bridging group T include CH2, CH2CH2, SiMe2, SiPh2, SiMePh, Si(CH2)3, Si(CH2)4, O, S, NPh, PPh, NMe, PMe, NEt, NPr, NBu, PEt, PPr, Me2SiOSiMe2, and PBu. In at least one embodiment, when Cp' is tetrahydro-s-indecenyl and T is R*2Si, then R* is not aryl. [0217] In some embodiments, R* is not aryl or substituted aryl. [0218] In some embodiments, T is represented by the formula ERd d 2 or (ER 2)2, where E is C, Si, or Ge, and each Rd is, independently, hydrogen, halogen, C1 to C20 hydrocarbyl (such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, or dodecyl) or a C1 to C20 substituted hydrocarbyl, and two Rd can form a cyclic structure including aromatic, partially saturated, or saturated cyclic or fused ring system. Preferably, T is a bridging group comprising carbon or silica, such as dialkylsilyl, such as T is selected from CH 2 , CH 2 CH 2 , C(CH 3 ) 2 , SiMe 2 , cyclotrimethylenesilylene (Si(CH 2 ) 3 ), cyclopentamethylenesilylene (Si(CH2)5) and cyclotetramethylenesilylene (Si(CH2)4). [0219] In some embodiments, Rd is not aryl or substituted aryl. [0220] Illustrative, but not limiting, examples of metallocenes for use in a catalyst system include: dimethylsilylene(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1- yl)(cyclododecylamido)M(R)2 (such as TiCl2 or TiMe2), dimethylsilylene(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2 (such as TiCl2 or TiMe2), dimethylsilylene(6,6-dimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(cyclododecylamido)M(R)2 (such as TiCl2 or TiMe2), dimethylsilylene (6,6-dimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2 (such as TiCl2 or TiMe2), dimethylsilylene(2,7,7-trimethyl-3,6,7,8-tetrahydro-as-indacen-3- yl)(cyclododecylamido)M(R)2 (such as TiCl2 or TiMe2), dimethylsilylene(2,7,7-trimethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(t-butylamido)M(R)2 (such as TiCl2 or TiMe2), dimethylsilylene(7,7-dimethyl-3,6,7,8-tetrahydro-as-indacen-3- yl)(cyclododecylamido)M(R)2 (such as TiCl2 or TiMe2), dimethylsilylene(7,7-dimethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(t-butylamido)M(R)2 (such as TiCl2 or TiMe2), µ-(CH3)2Si(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(l-adamantylamido)M(R)2; µ-(CH3)2Si(6,6-dimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(1-adamantylamido)M(R)2; µ-(CH3)2Si(2-methyl-6,6-diethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(l- adamantylamido)M(R)2; µ-(CH3)2Si(6,6-diethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(1-adamantylamido)M(R)2; µ-(CH3)2Si(2,7,7-trimethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(1-adamantylamido)M(R)2; µ-(CH3)2Si(7,7-dimethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(1-adamantylamido)M(R)2; µ-(CH3)2Si(2-methyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(1-adamantylamido)M(R)2; µ-(CH3)2Si(2-methyl-7,7-diethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(1- adamantylamido)M(R)2; µ-(CH3)2Si(7,7-diethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(1-adamantylamido)M(R)2; µ-(CH3)2Si(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; µ-(CH3)2Si(6,6-dimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; µ-(CH3)2Si(2-methyl-6,6-diethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; µ-(CH3)2Si(6,6-diethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; µ-(CH3)2Si(2,7,7-trimethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(t-butylamido)M(R)2; µ-(CH3)2Si(7,7-dimethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(t-butylamido)M(R)2; µ-(CH3)2Si(2-methyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(t-butylamido)M(R)2; µ-(CH3)2Si(2-methyl-7,7-diethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(t-butylamido)M(R)2; µ-(CH3)2Si(7,7-diethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(t-butylamido)M(R)2; µ-(CH3)2Si(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(cyclododecylamido)M(R)2; µ-(CH3)2Si(6,6-dimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(cyclododecylamido)M(R)2; µ-(CH3)2Si(2-methyl-6,6-diethyl-1,5,6,7-tetrahydro-s-indacen-1- yl)(cyclododecylamido)M(R)2; µ-(CH3)2Si(6,6-diethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(cyclododecylamido)M(R)2; µ-(CH3)2Si(2,7,7-trimethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(cyclododecylamido)M(R)2; µ-(CH3)2Si(7,7-dimethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(cyclododecylamido)M(R)2; µ-(CH3)2Si(2-methyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(cyclododecylamido)M(R)2; µ-(CH3)2Si(2-methyl-7,7-diethyl-3,6,7,8-tetrahydro-as-indacen-3- yl)(cyclododecylamido)M(R)2; µ-(CH3)2Si(7,7-diethyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(cyclododecylamido)M(R)2; µ-(CH2)3Si(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; µ-(CH2)4Si(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; µ-(CH2)5Si(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; µ-(CH3)2C(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; µ-(CH2)3Si(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; µ-(CH2)4Si(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; µ-(CH2)5Si(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; µ-(CH3)2C(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(t-butylamido)M(R)2; and µ-(CH3)2Si(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)(neopentylamido)M(R)2; where M is selected from a group consisting of Ti, Zr, and Hf and R is selected from halogen or C1 to C5 alkyl, such as R is a methyl group or a halogen group, (such as Cl, Br, I or F), preferably the compound is dimethylsilylene(2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-1- yl)(Z)Ti(R)2 or µ-(CH3)2Si(2-methyl-3,6,7,8-tetrahydro-as-indacen-3-yl)(Z)Ti(R)2, where Z is t-butylamido, adamantylamido, cyclooctylamido, cyclohexylamido or cyclododecylamido, and R is selected from halogen or C2 to C5 alkyl, i.e., R is not methyl. [0221] In at least one embodiment, a catalyst system includes µ-(CH3)2Si(η5-2,6,6- trimethyl-1,5,6,7-tetrahydro-s-indacen-1-yl)( tertbutylamido)M(R)2; where M is selected from a group consisting of Ti, Zr, and Hf and R is selected from halogen or C1 to C5 alkyl, such as, R is a methyl group. In an embodiment, M is Ti and R is Cl, Br or Me. [0222] In alternate embodiments, two or more different transition metal compounds may be used herein. For purposes of the present disclosure one transition metal compound is considered different from another if they differ by at least one atom. For example “Me2Si(2,7,7-Me3-3,6,7,8-tetrahydro-as-indacen-3-yl)(cyclohexylamido)TiCl2” is different from Me2Si(2,7,7-Me3-3,6,7,8-tetrahydro-as-indacen-3-yl)(n-butylamido)TiCl2 which is different from Me2Si(2,7,7-Me3-3,6,7,8-tetrahydro-as-indacen-3-yl)(n-butylamido)HfCl2. [0223] In at least one embodiment, one mono-tetrahydroindacenyl compound as described herein is used in the catalyst system. [0224] For further information on indacenyl catalyst compounds that are useful herein and methods to prepare them, please US 2015-0119539; US 2017-0320976, US 2016-0244535, US 2018-0094088; US 2019-0292282; US 2017-0342175; US 2019-0161560; US 2019-0119418; and US 9,458,254. Activators [0225] The terms “cocatalyst” and “activator” are used herein interchangeably and are defined to be any compound which can activate any one of the catalyst compounds described above by converting the neutral catalyst compound to a catalytically active catalyst compound cation. Non-limiting activators, for example, include alumoxanes, aluminum alkyls, ionizing activators, which may be neutral or ionic, and conventional-type cocatalysts. Activators typically include alumoxane compounds, modified alumoxane compounds, and ionizing anion precursor compounds that abstract a reactive, α-bound, metal ligand making the metal complex cationic and providing a charge-balancing non-coordinating or weakly coordinating anion. Alumoxane Activators [0226] Alumoxane activators are utilized as activators in the catalyst systems described herein. Alumoxanes are generally oligomeric compounds containing -Al(R1)-O- sub-units, where R1 is an alkyl group. Examples of alumoxanes include methylalumoxane (MAO), modified methylalumoxane (MMAO), ethylalumoxane and isobutylalumoxane. Alkylalumoxanes and modified alkylalumoxanes are suitable as catalyst activators, particularly when the abstractable ligand is an alkyl, halide, alkoxide or amide. Mixtures of different alumoxanes and modified alumoxanes may also be used. It may be preferable to use a visually clear methylalumoxane. A cloudy or gelled alumoxane can be filtered to produce a clear solution or clear alumoxane can be decanted from the cloudy solution. A useful alumoxane is a modified methyl alumoxane (MMAO) cocatalyst type 3A (commercially available from Akzo Chemicals, Inc. under the trade name Modified Methylalumoxane type 3A, covered under patent number US Patent No.5,041,584). [0227] When the activator is an alumoxane (modified or unmodified), some embodiments select the maximum amount of activator typically at up to a 5,000-fold molar excess Al/M over the catalyst compound (per metal catalytic site). The minimum activator-to-catalyst-compound is a 1:1 molar ratio. Alternate ranges include from 1:1 to 500:1, alternately from 1:1 to 200:1, alternately from 1:1 to 100:1, or alternately from 1:1 to 50:1. Non Coordinating Anion Activators [0228] Non-coordinating anion activators may also be used herein. The term "non- coordinating anion" (NCA) means an anion which either does not coordinate to a cation or which is only weakly coordinated to a cation thereby remaining sufficiently labile to be displaced by a neutral Lewis base. "Compatible" non-coordinating anions are those which are not degraded to neutrality when the initially formed complex decomposes. Further, the anion will not transfer an anionic substituent or fragment to the cation so as to cause it to form a neutral transition metal compound and a neutral by-product from the anion. Non-coordinating anions useful in accordance with the present disclosure are those that are compatible, stabilize the transition metal cation in the sense of balancing its ionic charge at +1, and yet retain sufficient lability to permit displacement during polymerization. [0229] It is within the scope of the present disclosure to use an ionizing or stoichiometric activator, neutral or ionic, such as tri (n-butyl) ammonium tetrakis (pentafluorophenyl) borate, a tris perfluorophenyl boron metalloid precursor or a tris perfluoronaphthyl boron metalloid precursor, polyhalogenated heteroborane anions (WO 1998/043983), boric acid (US Patent No. 5,942,459), in combination with the alumoxane or modified alumoxane activators. It is also within the scope of the present disclosure to use neutral or ionic activators in combination with the alumoxane or modified alumoxane activators. [0230] The catalyst systems of the present disclosure can include at least one non- coordinating anion (NCA) activator. Specifically, the catalyst systems may include an NCAs which either do not coordinate to a cation or which only weakly coordinate to a cation thereby remaining sufficiently labile to be displaced during polymerization. [0231] The terms “cocatalyst” and “activator” are used herein interchangeably and are defined to be any compound which can activate any one of the catalyst compounds described above by converting the neutral catalyst compound to a catalytically active catalyst compound cation. [0232] In at least one embodiment, boron containing NCA activators represented by the formula below can be used: Zd + ( Ad-) where: Z is (L-H) or a reducible Lewis acid; L is a neutral Lewis base; H is hydrogen; (L-H) is a Bronsted acid; Ad- is a boron containing non-coordinating anion having the charge d-; d is 1, 2, or 3. [0233] The cation component, Zd+ may include Bronsted acids such as protons or protonated Lewis bases or reducible Lewis acids capable of protonating or abstracting a moiety, such as an alkyl or aryl, from the bulky ligand metallocene containing transition metal catalyst precursor, resulting in a cationic transition metal species. [0234] The activating cation Zd + may also be a moiety such as silver, tropylium, carboniums, ferroceniums and mixtures, such as carboniums and ferroceniums. Such as Zd + is triphenyl carbonium. Reducible Lewis acids can be any triaryl carbonium (where the aryl can be substituted or unsubstituted, such as those represented by the formula: (Ar3C+), where Ar is aryl or aryl substituted with a heteroatom, a C1 to C40 hydrocarbyl, or a substituted C1 to C40 hydrocarbyl), such as the reducible Lewis acids in formula (14) above as “Z” include those represented by the formula: (Ph3C), where Ph is a substituted or unsubstituted phenyl, such as substituted with C1 to C40 hydrocarbyls or substituted a C1 to C40 hydrocarbyls, such as C1 to C20 alkyls or aromatics or substituted C1 to C20 alkyls or aromatics, such as Z is a triphenylcarbonium. [0235] When Zd + is the activating cation (L-H)d +, it is preferably a Bronsted acid, capable of donating a proton to the transition metal catalytic precursor resulting in a transition metal cation, including ammoniums, oxoniums, phosphoniums, silyliums, and mixtures thereof, such as ammoniums of methylamine, aniline, dimethylamine, diethylamine, N-methylaniline, diphenylamine, trimethylamine, triethylamine, N,N-dimethylaniline, methyldiphenylamine, pyridine, p-bromo N,N-dimethylaniline, p-nitro-N,N-dimethylaniline, phosphoniums from triethylphosphine, triphenylphosphine, and diphenylphosphine, oxomiuns from ethers such as dimethyl ether diethyl ether, tetrahydrofuran and dioxane, sulfoniums from thioethers, such as diethyl thioethers, tetrahydrothiophene, and mixtures thereof. [0236] The activating cation Zd + may also be a moiety such as [R1', R2',R3'EH]d+, where E is N or P, d is 12 or 3, and R1', R2', and R3' are independently a C1 to C50 hydrocarbyl group optionally substituted with one or more alkoxy groups, silyl groups, a halogen atoms, or halogen containing groups, wherein together R1', R2', and R3' comprise 15 or more carbon atoms (such as 18 or more carbon atoms, such as 20 or more carbon atoms, such as 22 or more carbon atoms, such as 25 or more carbon atoms, such as 30 or more carbon atoms, such as 35 or more carbon atoms, such as 38 or more carbon atoms, such as 40 or more carbon atoms, such as 15 to 100 carbon atoms, such as 25 to 75 carbon atoms). [0237] Useful cation components, Zd + , include those represented by the formula:
Figure imgf000055_0001
[0238] Useful cation components, Zd +, include those represented by the formulas:
Figure imgf000056_0001
[0239] The anion component Ad- includes those having the formula [Mk+Qn]d- wherein k is 1, 2, or 3; n is 1, 2, 3, 4, 5, or 6 (such as 1, 2, 3, or 4); n - k = d; M is an element selected from Group 13 of the Periodic Table of the Elements, such as boron or aluminum, and Q is independently a hydride, bridged or unbridged dialkylamido, halide, alkoxide, aryloxide, hydrocarbyl, substituted hydrocarbyl, halocarbyl, substituted halocarbyl, and halosubstituted- hydrocarbyl radicals, said Q having up to 20 carbon atoms with the proviso that in not more than 1 occurrence is Q a halide. Preferably, each Q is a fluorinated hydrocarbyl group having 1 to 20 carbon atoms, such as each Q is a fluorinated aryl group, and such as each Q is a pentafluoryl aryl group. Examples of suitable Ad- also include diboron compounds as disclosed in US Patent No.5,447,895, which is fully incorporated herein by reference. [0240] Illustrative, but not limiting, examples of boron compounds which may be used as an activating cocatalyst are the compounds described as (and particularly those specifically listed as) activators in US 8,658,556, which is incorporated by reference herein. [0241] For example, the ionic stoichiometric activator Zd + (Ad-) is one or more of N,N- dimethylanilinium tetra(perfluorophenyl)borate, N,N-dimethylanilinium tetrakis(perfluoronaphthyl)borate, N,N-dimethylanilinium tetrakis(perfluorobiphenyl)borate, N,N-dimethylanilinium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, triphenylcarbenium tetrakis(perfluoronaphthyl)borate, triphenylcarbenium tetrakis(perfluorobiphenyl)borate, triphenylcarbenium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, or triphenylcarbenium tetra(perfluorophenyl)borate. [0242] Bulky activators are also useful herein as NCAs. “Bulky activator” as used herein refers to anionic activators represented by the formula: or
Figure imgf000057_0001
R R where: each R1 is, indep
Figure imgf000057_0002
endently, a halide, such as a fluoride; Ar is substituted or unsubstituted aryl group (such as a substituted or unsubstituted phenyl), such as substituted with C1 to C40 hydrocarbyls, such as C1 to C20 alkyls or aromatics; each R2 is, independently, a halide, a C6 to C20 substituted aromatic hydrocarbyl group or a siloxy group of the formula –O-Si-Ra, where Ra is a C1 to C20 hydrocarbyl or hydrocarbylsilyl group (such as R2 is a fluoride or a perfluorinated phenyl group); each R3 is a halide, C6 to C20 substituted aromatic hydrocarbyl group or a siloxy group of the formula –O-Si-Ra, where Ra is a C1 to C20 hydrocarbyl or hydrocarbylsilyl group (such as R3 is a fluoride or a C6 perfluorinated aromatic hydrocarbyl group); wherein R2 and R3 can form one or more saturated or unsaturated, substituted or unsubstituted rings (such as R2 and R3 form a perfluorinated phenyl ring); and L is an neutral Lewis base; (L-H)+ is a Bronsted acid; d is 1, 2, or 3; wherein the anion has a molecular weight of greater than 1020 g/mol; wherein at least three of the substituents on the B atom each have a molecular volume of greater than 250 cubic Å, alternately greater than 300 cubic Å, or alternately greater than 500 cubic Å. [0243] For example, (Ar3C)d + is (Ph3C)d +, where Ph is a substituted or unsubstituted phenyl, such as substituted with C1 to C40 hydrocarbyls or substituted C1 to C40 hydrocarbyls, such as C1 to C20 alkyls or aromatics or substituted C1 to C20 alkyls or aromatics. [0244] “Molecular volume” is used herein as an approximation of spatial steric bulk of an activator molecule in solution. Comparison of substituents with differing molecular volumes allows the substituent with the smaller molecular volume to be considered “less bulky” in comparison to the substituent with the larger molecular volume. Conversely, a substituent with a larger molecular volume may be considered more bulky than a substituent with a smaller molecular volume. [0245] Molecular volume may be calculated as reported in “A Simple ‘Back of the Envelope’ Method for Estimating the Densities and Molecular Volumes of Liquids and Solids,” Journal of Chemical Education, v.71(11), November 1994, pp. 962-964. Molecular volume (MV), in units of cubic Å, is calculated using the formula: MV = 8.3Vs, where Vs is the scaled volume. Vs is the sum of the relative volumes of the constituent atoms, and is calculated from the molecular formula of the substituent using the following table of relative volumes. For fused rings, the Vs is decreased by 7.5% per fused ring. El t R l ti V l e [0246] For a list
Figure imgf000058_0001
of particularly useful Bulky activators please see US 8,658,556, which is incorporated by reference herein. [0247] In another embodiment, one or more of the NCA activators is chosen from the activators described in US 6,211,105. [0248] Activators can include N,N-dimethylanilinium tetrakis(perfluoronaphthyl)borate, N,N-dimethylanilinium tetrakis(perfluorobiphenyl)borate, N,N-dimethylanilinium tetrakis(perfluorophenyl)borate, N,N-dimethylanilinium tetrakis(3,5- bis(trifluoromethyl)phenyl)borate, triphenylcarbenium tetrakis(perfluoronaphthyl)borate, triphenylcarbenium tetrakis(perfluorobiphenyl)borate, triphenylcarbenium tetrakis(3,5- bis(trifluoromethyl)phenyl)borate, triphenylcarbenium tetrakis(perfluorophenyl)borate, [Ph3C+][B(C6F5)4-], [Me3NH+][B(C6F5)4-]; 1-(4-(tris(pentafluorophenyl)borate)-2,3,5,6- tetrafluorophenyl)pyrrolidinium; and tetrakis(pentafluorophenyl)borate, 4-(tris(pentafluorophenyl)borate)-2,3,5,6-tetrafluoropyridine. [0249] In at least one embodiment, the activator comprises a triaryl carbonium (such as triphenylcarbenium tetraphenylborate, triphenylcarbenium tetrakis(pentafluorophenyl)borate, triphenylcarbenium tetrakis-(2,3,4,6-tetrafluorophenyl)borate, triphenylcarbenium tetrakis(perfluoronaphthyl)borate, triphenylcarbenium tetrakis(perfluorobiphenyl)borate, triphenylcarbenium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate). [0250] In another embodiment, the activator comprises one or more of trialkylammonium tetrakis(pentafluorophenyl)borate, N,N-dialkylanilinium tetrakis(pentafluorophenyl)borate, N,N-dimethyl-(2,4,6-trimethylanilinium) tetrakis(pentafluorophenyl)borate, trialkylammonium tetrakis-(2,3,4,6-tetrafluorophenyl) borate, N,N-dialkylanilinium tetrakis- (2,3,4,6-tetrafluorophenyl)borate, trialkylammonium tetrakis(perfluoronaphthyl)borate, N,N-dialkylanilinium tetrakis(perfluoronaphthyl)borate, trialkylammonium tetrakis(perfluorobiphenyl)borate, N,N-dialkylanilinium tetrakis(perfluorobiphenyl)borate, trialkylammonium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, N,N-dialkylanilinium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, N,N-dialkyl-(2,4,6-trimethylanilinium) tetrakis(3,5-bis(trifluoromethyl)phenyl)borate, di-(i-propyl)ammonium tetrakis(pentafluorophenyl)borate, (where alkyl is methyl, ethyl, propyl, n-butyl, sec-butyl, or t-butyl). [0251] Activator compounds that are particularly useful in this invention include one or more of: N,N-di(hydrogenated tallow)methylammonium [tetrakis(perfluorophenyl) borate], N-methyl-4-nonadecyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-hexadecyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-tetradecyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-dodecyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-decyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-octyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-hexyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-butyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-octadecyl-N-decylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-nonadecyl-N-dodecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-nonadecyl-N-tetradecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-4-nonadecyl-N-hexadecylanilinium [tetrakis(perfluorophenyl)borate], N-ethyl-4-nonadecyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-N,N-dioctadecylammonium [tetrakis(perfluorophenyl)borate], N-methyl-N,N-dihexadecylammonium [tetrakis(perfluorophenyl)borate], N-methyl-N,N-ditetradecylammonium [tetrakis(perfluorophenyl)borate], N-methyl-N,N-didodecylammonium [tetrakis(perfluorophenyl)borate], N-methyl-N,N-didecylammonium [tetrakis(perfluorophenyl)borate], N-methyl-N,N-dioctylammonium [tetrakis(perfluorophenyl)borate], N-ethyl-N,N-dioctadecylammonium [tetrakis(perfluorophenyl)borate], N,N-di(octadecyl)tolylammonium [tetrakis(perfluorophenyl)borate], N,N-di(hexadecyl)tolylammonium [tetrakis(perfluorophenyl)borate], N,N-di(tetradecyl)tolylammonium [tetrakis(perfluorophenyl)borate], N,N-di(dodecyl)tolylammonium [tetrakis(perfluorophenyl)borate], N-octadecyl-N-hexadecyl-tolylammonium [tetrakis(perfluorophenyl)borate], N-octadecyl-N-hexadecyl-tolylammonium [tetrakis(perfluorophenyl)borate], N-octadecyl-N-tetradecyl-tolylammonium [tetrakis(perfluorophenyl)borate], N-octadecyl-N-dodecyl-tolylammonium [tetrakis(perfluorophenyl)borate], N-octadecyl-N-decyl-tolylammonium [tetrakis(perfluorophenyl)borate], N-hexadecyl-N-tetradecyl-tolylammonium [tetrakis(perfluorophenyl)borate], N-hexadecyl-N-dodecyl-tolylammonium [tetrakis(perfluorophenyl)borate], N-hexadecyl-N-decyl-tolylammonium [tetrakis(perfluorophenyl)borate], N-tetradecyl-N-dodecyl-tolylammonium [tetrakis(perfluorophenyl)borate], N-tetradecyl-N-decyl-tolylammonium [tetrakis(perfluorophenyl)borate], N-dodecyl-N-decyl-tolylammonium [tetrakis(perfluorophenyl)borate], N-methyl-N-octadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-N-hexadecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-N-tetradecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-N-dodecylanilinium [tetrakis(perfluorophenyl)borate], N-methyl-N-decylanilinium [tetrakis(perfluorophenyl)borate], and N-methyl-N-octylanilinium [tetrakis(perfluorophenyl)borate]. [0252] Additional useful activators and the synthesis of useful non-aromatic-hydrocarbon soluble activators, are described in USSN 16/394,166 filed April 25, 2019, USSN 16/394,186, filed April 25, 2019, and USSN 16/394,197, filed April 25, 2019, which are incorporated by reference herein. [0253] Particularly useful activators also include dimethylaniliniumtetrakis (pentafluorophenyl) borate and dimethyl anilinium tetrakis(heptafluoro-2-naphthyl) borate. For a more detailed description of useful activators please see WO 2004/026921 page 72, paragraph [00119] to page 81 paragraph [00151]. A list of particularly useful activators that can be used in the practice of this invention may be found at page 72, paragraph [00177] to page 74, paragraph [00178] of WO 2004/046214. [0254] The typical NCA activator-to-catalyst ratio, e.g., all NCA activators-to-catalyst ratio is about a 1:1 molar ratio. Alternate ranges include from 0.1:1 to 100:1, alternately from 0.5:1 to 200:1, alternately from 1:1 to 500:1 alternately from 1:1 to 1000:1. A particularly useful range is from 0.5:1 to 10:1, such as 1:1 to 5:1. [0255] Activators useful herein also include those described in US 7,247,687 at column 169, line 50 to column 174, line 43, particularly column 172, line 24 to column 173, line 53. [0256] It is also within the scope of the present disclosure that the catalyst compounds can be combined with combinations of alumoxanes and NCA's (see for example, US 5,153,157, US 5,453,410, EP 0573120 B1, WO 1994/007928, and WO 1995/014044 which discuss the use of an alumoxane in combination with an ionizing activator). [0257] The catalyst systems used herein preferably contain 0 ppm (alternately less than 1 ppm) of residual aromatic hydrocarbon. Preferably, the catalyst systems used herein contain 0 ppm (alternately less than 1 ppm) of residual toluene. Optional Scavengers or Co-Activators [0258] In addition to the activator compounds, scavengers, chain transfer agents or co- activators may be used. Aluminum alkyl or organoaluminum compounds which may be utilized as scavengers or co-activators include, for example, trimethylaluminum, triethylaluminum, triisobutylaluminum, tri-n-hexylaluminum, tri-n-octylaluminum, and diethyl zinc. [0259] Useful chain transfer agents that may also be used herein are typically a compound represented by the formula AlR3, ZnR2 (where each R is, independently, a C1-C8 aliphatic radical, such as methyl, ethyl, propyl, butyl, penyl, hexyl octyl or an isomer thereof) or a combination thereof, such as diethyl zinc, trimethylaluminum, triisobutylaluminum, trioctylaluminum, or a combination thereof. Supports [0260] In some embodiments, the complexes described herein may be supported (with or without an activator) by any method effective to support other coordination catalyst systems, effective meaning that the catalyst so prepared can be used for oligomerizing or polymerizing olefin in a heterogeneous process. The catalyst precursor, activator, co-activator if needed, suitable solvent, and support may be added in any order or simultaneously. Typically, the complex and activator may be combined in solvent to form a solution. Then the support is added, and the mixture is stirred for 1 minute to 10 hours. The total solution volume may be greater than the pore volume of the support, but some embodiments limit the total solution volume below that needed to form a gel or slurry (about 90% to 400%, such as about 100-200% of the pore volume). After stirring, the residual solvent is removed under vacuum, typically at ambient temperature and over 10-16 hours. But greater or lesser times and temperatures are possible. [0261] The complex may also be supported absent the activator; in that case, the activator (and co-activator if needed) is added to a polymerization process's liquid phase. Additionally, two or more different complexes may be placed on the same support. Likewise, two or more activators or an activator and co-activator may be placed on the same support. [0262] Suitable solid particle supports are typically comprised of polymeric or refractory oxide materials, each being porous. Preferably any support material that has an average particle size greater than 10 µm is suitable for use. Various embodiments select a porous support material, such as for example, talc, inorganic oxides, inorganic chlorides, for example magnesium chloride and resinous support materials such as polystyrene polyolefin or polymeric compounds or any other organic support material and the like. Some embodiments select inorganic oxide materials as the support material including Group-2, -3, -4, -5, -13, or -14 metal or metalloid oxides. Some embodiments select the catalyst support materials to include silica, alumina, silica-alumina, and their mixtures. Other inorganic oxides may serve either alone or in combination with the silica, alumina, or silica-alumina. These are magnesia, titania, zirconia, and the like. Lewis acidic materials such as montmorillonite and similar clays may also serve as a support. In this case, the support can optionally double as the activator component, however, an additional activator may also be used. [0263] The support material may be pretreated by any number of methods. For example, inorganic oxides may be calcined, chemically treated with dehydroxylating agents such as aluminum alkyls and the like, or both. [0264] As stated above, polymeric carriers will also be suitable in accordance with the present disclosure, see for example the descriptions in WO 1995/015815 and US 5,427,991. The methods disclosed may be used with the catalyst complexes, activators or catalyst systems of the present disclosure to adsorb or absorb them on the polymeric supports, particularly if made up of porous particles, or may be chemically bound through functional groups bound to or in the polymer chains. [0265] Useful supports typically have a surface area of 10-700 m2/g, a pore volume of 0.1-4.0 cc/g and an average particle size of 10-500 µm. Some embodiments select a surface area of 50-500 m2/g, a pore volume of 0.5-3.5 cc/g, or an average particle size of 20-200 µm. Other embodiments select a surface area of 100-400 m2/g, a pore volume of 0.8-3.0 cc/g, and an average particle size of 30-100 µm. Useful supports typically have a pore size of 10-1,000 Angstroms, alternatively 50-500 Angstroms, or 75-350 Angstroms. [0266] The catalyst complexes described herein are generally deposited on the support at a loading level of 10-100 micromoles of complex per gram of solid support; alternately 20-80 micromoles of complex per gram of solid support; or 40-60 micromoles of complex per gram of support. But greater or lesser values may be used provided that the total amount of solid complex does not exceed the support's pore volume. [0267] In an alternate embodiment, catalyst complexes and catalyst systems described herein may be present on a fluorided support, e.g., a support, desirably particulate and porous, which has been treated with at least one inorganic fluorine containing compound. For example, the fluorided support composition can be a silicon dioxide support wherein a portion of the silica hydroxyl groups has been replaced with fluorine or fluorine containing compounds. For example, a useful support herein, is a silica support treated with ammonium hexafluorosilicate and/or ammonium tetrafluoroborate fluorine compounds. Typically the fluorine concentration present on the support is in the range of 0.1 to 25 wt%, alternately 0.19 to 19 wt%, alternately from 0.6 to 3.5 wt%, based upon the weight of the support. [0268] In some embodiments, the catalyst system comprises fluorided silica, alkylalumoxane activator, and the bridged monocyclopentadienyl group 4 transition metal compound, where the fluorided support has preferably not been calcined at a temperature of 400°C or more. [0269] In some embodiments, the catalyst system the reaction product of fluorides silica support, alkylalumoxane activator and µ-(CH3)2Si(η5-2,6,6-trimethyl-1,5,6,7-tetrahydro-s- indacen-1-yl)(tertbutylamido)M(R)2; where M is selected from a group consisting of Ti, Zr, and Hf and R is selected from halogen or C1 to C5 alkyl, where the fluorided silica support has preferably not been calcined at a temperature of 400°C or more. [0270] The catalyst compound may be present on a support at 1 to 100 µmol/g supported catalyst, such as 20-60 µmol/g supported catalyst. [0271] The present disclosure also relates to metallocene catalyst compositions comprising the reaction product of at least three components: (1) one or more bridged metallocenes having one tetrahydroindacenyl group; (2) one or more alkylalumoxane activators; and (3) one or more fluorided support compositions, where the fluorided support composition has not been calcined at 400°C or more, such as the fluorided support composition has been calcined at a temperature of 100°C to 395°C, alternately 125°C to 350°C, alternately 150°C to 300°C. [0272] Typically, the fluorided supports described herein are prepared by combining a solution of polar solvent (such as water) and fluorinating agent (such as SiF4 or (NH4)2SiF6) with a slurry of support (such as a toluene slurry of silica), then drying until it is free flowing, and optionally, calcining (typically at temperatures over 100°C for at least 1 hour). The supports are then combined with activator(s) and catalyst compound (separately or together). [0273] For more information on fluorided supports and methods to prepare them, please see USSN 62/149,799, filed April 20, 2015 (and all cases claiming priority to or the benefit of USSN 62/149,799); USSN 62/103372, filed January 14, 2015 (and all cases claiming priority to or the benefit of USSN 62/103372); and PCT/US2015/067582, filed December 28, 2015 which are incorporated by reference herein. ADDITIONAL ASPECTS [0274] The present disclosure provides, among others, the following aspects, each of which may be considered as optionally including any alternate aspects. Clause 1. A copolymer comprising: about 50 wt% to about 99.9 wt% C6-C60 linear α-olefin units, based on the weight of the copolymer; diene units; and C2-C10 α-olefin comonomer units different than the C6-C60 linear α-olefin units. Clause 2. The copolymer of Clause 1, wherein the copolymer comprises ethylene units. Clause 3. The copolymer of Clauses 1 or 2, wherein the copolymer has about 90 wt% to about 99 wt% C6-C60 linear α-olefin units, based on the weight of the copolymer. Clause 4. The copolymer of any of Clauses 1 to 3, wherein the C6-C60 linear α-olefin comprises a C16–C26 linear α-olefin. Clause 5. The copolymer of any of Clauses 1 to 4, wherein the C6-C60 linear α-olefin comprises 1-decene or 1-octadecene. Clause 6. The copolymer of any of Clauses 1 to 5, wherein the copolymer comprises of about 1 wt% to about 10 wt% diene units, based on the weight of the copolymer. Clause 7. The copolymer of any of Clauses 1 to 6, wherein the copolymer comprises of about 2 wt% to about 5 wt% diene units, based on the weight of the copolymer. Clause 8. The copolymer of any of Clauses 1 to 7, wherein the diene comprises C7-C9 dienes. Clause 9. The copolymer of any of Clauses 1 to 8, wherein the diene is selected from the group consisting of vinylnorbornene, norbornadiene, 5-ethylidene-2-norbornene, 5-vinyl-2- norbornene, divinylbenzene, dicyclopentadiene, and combination(s) thereof. Clause 10. The copolymer of any of Clauses 1 to 9, wherein the diene comprises C7 diene. Clause 11. The copolymer of any of Clauses 1 to 10, wherein the diene is 5-ethylidene- 2-norbornene. Clause 12. The copolymer of any of Clauses 1 to 11, wherein the diene is an α,Ω-diene. Clause 13. The copolymer of any of Clauses 1 to 12, wherein the copolymer comprises about 1.5 wt% to about 2.5 wt% ethylene units, based on the weight of the copolymer. Clause 14. The copolymer of any of Clauses 1 to 13, wherein the copolymer comprises about 8 wt% to about 12 wt% ethylene units, based on the weight of the copolymer. Clause 15. The copolymer of any of Clauses 1 to 14, wherein the copolymer has an Mw value of about 100,000 g/mol to about 500,000 g/mol. Clause 16. The copolymer of any of Clauses 1 to 15, wherein the copolymer has an Mw value of about 200,000 g/mol to about 300,000 g/mol. Clause 17. The copolymer of any of Clauses 1 to 16, wherein the copolymer has an Mn value of about 70,000 g/mol to about 200,000 g/mol. Clause 18. The copolymer of any of Clauses 1 to 17, wherein the copolymer has an Mw/Mn value from 1 to 5. Clause 19. The copolymer of any of Clauses 1 to 18, wherein the copolymer has an Mw/Mn value from 2 to 3. Clause 20. The copolymer of any of Clauses 1 to 19, wherein the copolymer has a glass transition temperature (Tg) of about -50°C to about -70°C. Clause 21. The copolymer of any of Clauses 1 to 20, wherein the copolymer has a crystallization temperature (Tc) of about 60°C to about 80°C. Clause 22. A crosslinked copolymer having one or more of (or each of) the following properties: a tensile set @200% deformation of about 0.1% to about 50% or less; a tensile strength at 23°C of about 50 kPa to about 1,000 kPa; an Edis of about 1 kJ/m3 to about 10 kJ/m3; an elongation at break of about 10% to about 1,000%; a Young’s modulus (at 40°C) of about 50 kPa to about 1,000 kPa; a glass transition temperature (Tg) of about –100°C to about 0°C; a melting temperature (Tm) of about 50°C to about 150°C; and/or a temperature of crystallization (Tc) of about 10°C to about 150°C. Clause 23. The crosslinked copolymer of any of Clauses 1 to 22, wherein the crosslinked copolymer has a tensile set of about 3% to about 7%. Clause 24. The crosslinked copolymer of any of Clauses 1 to 23, wherein the crosslinked copolymer has a tensile strength of about 400 kPa to about 650 kPa. Clause 25. The crosslinked copolymer of any of Clauses 1 to 24, wherein the crosslinked copolymer has an elongation at break of about 400% to about 500%. Clause 26. The crosslinked copolymer of any of Clauses 1 to 25, wherein the crosslinked copolymer has an elongation at break of about 150% to about 250%. Clause 27. The crosslinked copolymer of any of Clauses 1 to 26, wherein the crosslinked copolymer has a Young’s modulus (at 40°C) of about 500 kPa to about 600 kPa. Clause 28. The crosslinked copolymer of any of Clauses 1 to 27, wherein the crosslinked copolymer has a glass transition temperature (Tg) of about –70°C to about –60°C. Clause 29. The crosslinked copolymer of any of Clauses 1 to 28, wherein the crosslinked copolymer has a melting temperature (Tm) of about 90°C to about 110°C. Clause 30. The crosslinked copolymer of any of Clauses 1 to 29, wherein the crosslinked copolymer has a melting temperature (Tm) of about 110°C to about 135°C. Clause 31. The crosslinked copolymer of any of Clauses 1 to 30, wherein the crosslinked copolymer has a temperature of crystallization (Tc) of about 60°C to about 80°C. Clause 32. The crosslinked copolymer of any of Clauses 1 to 31, wherein the crosslinked copolymer has a temperature of crystallization (Tc) of about 10°C to about 35°C. Clause 33. An impact copolymer comprising: from 10 wt% to 80 wt% of the copolymer of any of Clauses 1 to 32, based on the weight of the impact copolymer; and a polypropylene. Clause 34. The impact copolymer of Clause 33, wherein the impact copolymer comprises: a continuous phase comprising the polypropylene; and a dispersed phase comprising the copolymer. Clause 35. The impact copolymer of Clauses 33 or 34, wherein the dispersed phase comprises less than 5 wt% polypropylene, based on the weight of the dispersed phase. Clause 36. The impact copolymer of any of Clauses 33 to 35, wherein the impact copolymer has a compressive strength at 23°C of about 100 MPa to about 500 MPa. Clause 37. The impact copolymer of any of Clauses 33 to 36, wherein the impact copolymer is free of oil. Clause 38. The impact copolymer of any of Clauses 33 to 37, wherein the impact copolymer has less than 150 phr oil. Clause 39. The impact copolymer of any of Clauses 33 to 38, wherein the impact copolymer has less than 25 phr oil. Clause 40. The impact copolymer of any of Clauses 33 to 39, wherein the impact copolymer has 0 phr oil.
Clause 41. An article comprising the impact copolymer of any of Clauses 33 to 40.
Clause 42. A process to produce an impact copolymer comprising: combining a first component comprising polypropylene with from 10 wt% to 80 wt% of a second component comprising the copolymer of Clause 1 or Clause 22, under melt conditions, to form a homogenous melt mixture; and cooling the melt mixture to form the impact copolymer comprising the first component as a continuous phase and the second component as a dispersed phase, Clause 43. A process to produce the copolymer of any of Clauses 1 to 32, the process comprising: introducing a Ce-Ceo linear α-olefin, a diene, and optionally C2-C10 a-olefin comonomer (different than the Ce-Ceo linear a-olefin) to a catalyst system comprising an activator and a tetrahydroindacenyl catalyst compound. Clause 44. The process of Clause 43, wherein the process occurs at a temperature of about 0°C to about 300°C, at a pressure in the range of about 0.35 MPa to about 16 MPa, and at a time up to 300 minutes.
Clause 45. The process of Clauses 43 or 44, wherein: the linear a-olefin comprises 1-decene and/or 1-octadecene, and the diene comprises 5-ethylidene-2-norbomene.
Clause 46. The process of any of Clauses 43 to 45, wherein the tetrahydroindacenyl catalyst compound IS μ-(CH3)2Si(η 5-2,6,6-trimethyl-1,5,6,7-tetrahydro-s-indacen-l- yl)(tertbutylamido)M(R)2; wherein M is selected from the group consisting of Ti, Zr, and Hf, and R is selected from the group consisting of halogen and C1 to C5 alkyl. Clause 47. The process of of any of Clauses 43 to 46, wherein the activator is represented by the formula:
[R1' R2' R3' EH] d+[Mtk+ Qn]d- wherein:
E is nitrogen or phosphorous; d is 1, 2 or 3; k is 1, 2, or 3; n is 1, 2, 3, 4, 5, or 6; n — k = d;
R1' , R2' , and R3' are independently a C1 to C50 hydrocarbyl group optionally substituted with one or more alkoxy groups, silyl groups, a halogen atoms, or halogen containing groups, wherein R1' , R2' , and R3' together comprise 15 or more carbon atoms; ^3 is an element selected from group 13 of the Periodic Table of the Elements; and each 6 is independently a hydride, bridged or unbridged dialkylamido, halide, alkoxide, aryloxide, hydrocarbyl, substituted hydrocarbyl, halocarbyl, substituted halocarbyl, or halosubstituted-hydrocarbyl radical. Clause 48. The process of any of Clauses 43 to 46, wherein the activator is represented by the formula: Zd + ( Ad-) wherein Ad- is a non-coordinating anion having the charge d-; and d is 1, 2 or 3 and (Z)d + is represented by one or more of: 10 11 12
Figure imgf000068_0001
31 32 33
Figure imgf000069_0002
[0275] GPC: The molecular weight distribution, molecular weight moments (Mw, Mn, Mw/Mn) and long chain branching indices were determined by using a GPC hyphenated with multiple detectors including DRI, Viscometer and Light Scattering detector. The conventional molecular weight was determined by combining universal calibration relationship with the column calibration which was performed with a series of monodispersed polystyrene (PS) standards ranging from 300 g/mole to 12,000,000 g/mole. The molecular weight “M” at each elution volume was calculated with following equation: log(K /K ) a α PS α P α 1 log M S log M a α 1 a α 1 PS where the variables with
Figure imgf000069_0001
subscript "PS" stand for polystyrene while those without a subscript are for the test samples. In this method, aPS = 0.7362 and KPS = 0.0000957 while “a” and “K” for the copolymer samples were obtained as a = 738 and K = 0.000072 for linear octadecene–ethylene –diene terpolymers, and a = 0.737 and K = 0.000117 for decene-ethylene- diene terpolymers by fitting the logIV vs. logM curve for a linear reference sample, where the IV stands for the intrinsic viscosity. [0276] The foregoing discussion can be further described with reference to the following non-limiting examples. ENB = 5-ethylidene-2-norbornene. Alpha-olefin ethylene diene polymer (AOEDM) synthesis. [0277] Alpha-olefins (AO) ranging from 1-hexene (C6H14) to 1-hexacontane (C60H122) are copolymerized with ethylene and a diene by organo‐metallic coordinative insertion polymerization using catalyst 1 (the structure shown below).
Preparation of 1-d
Figure imgf000070_0001
ecene-ethylene-(5-ethylidene-2-norbornene) (DEDM) and 1-octadecene-ethyelene-ENB (ODEDM) terpolymers. [0278] The AO (1-decene:D or 1-octadecene:OD), ENB and isohexane were mixed in a 2L batch reactor. Some samples were prepared without ENB, as controls. The reactor was equilibrated at a temperature of 80°C, and then pressurized with ethylene feed. The mixture was stirred rapidly and a toluene solution (4ml) of Catalyst 1 (20mg+10ml toluene) and a toluene solution (4.5 ml) of N,N-Dimethylanilinium tetrakis(heptafluoronaphthalen-2- yl)borate (Activator 1) (60 mg +10 ml Toluene) were injected to the reactor. After 30 minutes, the reaction was quenched by adding methanol. The resulting thick solution was poured into stirring methanol (4 L). The precipitate was redissolved in isohexane and precipitated a second time in methanol (4 L). The resulting polymer was washed with acetone and dried overnight under the hood. The polymer was further dried in a vacuum oven at 90°C overnight. [0279] Table 1 shows synthesis conditions of DE, DEDM, ODE, and ODEM examples prepared via the procedure described above, as well as the Mw, PDI and composition, measured by GPC and NMR, respectively. C13NMR and H1NMR results confirm the ability of Catalyst 1 to incorporate large amounts of AO and ENB in the compolymer, when the reaction is performed in the presence of ethylene. The simplified structure of the random terpolymers is shown below.
Figure imgf000070_0002
Table 1. AOEDM synthesis conditions. s l )
Figure imgf000071_0001
Curing behavior of the AOEDM terpolymers. [0280] To assess the feasibility of the terpolymers to undergo crosslinking, via reaction of the available double bonds in the diene comonomers, two of the DEDM and one of the ODEDM terpolymers were mixed with three different curative systems: (1) dicumyl peroxide (1 phr), sulfur (2phr), and photoinitiator 1-hydroxycyclohexyl phenyl ketone (1 phr). FIGS.1 to 3 demonstrate the curing behavior typical of diene-containing rubbers. Cure reversion is observed in the sulfur formulations, which is typical for this type of curing system. UV-curing is very slow, compared to the thermal curing (FIG. 3), which allows good crosslink density control. FIG. 1 shows low modulus of these elastomers without the need to add solvent to them: ~250 kPa for the DEDMs and ~30 kPa for the ODEDM. [0281] For crosslinking, the curatives were mixed with the copolymers by solution blending. The polymers were dissolved in isohexane (10 wt % solutions) and the curative(s) was added to the solution. Then the solutions were poured on an aluminum tray and the solvent evaporated for 20 hours under ambient conditions and subsequently for 3 hours under vacuum at 80°C. [0282] The curing kinetics was measured in the ARES-G2 rheometer (TA Instruments). A small sample of the green (uncured) sample was molded into a disc with 8 mm diameter and 4 mm height. The disc was loaded in the rheometer with parallel plate geometry inside the force convection oven, which was equilibrated at 80°C. The temperature was quickly raised to 160°C and maintained for 60 minutes. During that time, the elastic modulus is being recorded and plotted as a function of time. [0283] The samples were also cured in a hot press heated at 160°C where thin flat specimens were molded for tensile tests. Thermal properties of the AOEDM terpolymers. [0284] DSC measurements were used to measure the thermal transitions in the AOEDM terpolymers. The temperatures corresponding to the glass transition, Tg, melting (DSC peak), Tm and crystallization (DSC onset), Tc, are tabulated in Table 2. The DE and DEDM Example 13 to Example 18 showed no signs of crystallization/melting, whereas Example 19 and DEDM Example 20 showed a weak crystallization, perhaps due to long ethylene runs along the backbone. Crosslinking of the terpolymers slightly reduces the Tm and Tc values, but does not hinder the crystallization. [0285] For DSC, a 4 mg to 8 mg sample was loaded in a hermetic DSC pan. DSC measurements were carried out using a DSC2500TM (TA InstrumentsTM) with a 10°C/min heating rate. The heat flow data during temperature ramps from 150°C to -150°C and from -150°C to 150°C were collected to measure the thermal transitions, Tg, Tm and Tc. [0286] The ODE sample shows the typical crystallization/ melting peaks of polyoctadecene which is associated to side chain crystallization, as described in Macromolecules (2018), v.51, pp.872-883. In contrast, all the ODEM samples showed two peaks during crystallization and two peaks during melting (FIG.5). FIG. 6 shows DSC thermograms of the uncured ODEDM Example 24 samples before and after curing with CPD and sulfur. It is clear that upon crosslinking, the high temperature Tc and Tm peaks disappear, which implies that the side- chain crystallization is hindered. This renders softer elastomers, as the crystallinity is reduced.
Table 2. Thermal transitions in AOEDM terpolymers. C /C / 1 ( ) ( ) Elastic p
Figure imgf000073_0001
roperties of cure AOEDM terpolymers. [0287] Tensile and hysteresis test on small dogbone specimens of the DCP-cured DEDM (Example 20) and ODEDM (Example 24) were performed using the RSA-G2 instrument (TA Instruments). Measured values of Young's modulus, E, strain to break, and tensile strength are tabulated in Table 3. FIG. 7 shows the stress strain curves for the two samples. The Young's modulus of the DEDM sample is significantly higher than the corresponding value for the ODEDM, reflecting the elastic modulus difference observed during the cure kinetics tests. (FIG. 1). The ODEDM sample was measured at two temperatures: at 25°C right below Tm and at 40°C above Tm. Above Tm, the Young modulus is significantly lower, and the extensibility is significantly improved. However, the tensile strength remains the same. A very remarkable behavior observed in the ODEDM sample is the very low hysteresis and the very small tensile set (5.4%) after a deformation of 200 %. Table 3. Tensile properties of DCP-cured AOEDM terpolymers.
Figure imgf000074_0001
[0288] Compression tests of the DCP-cured ODEDM (Example 24) sample were carried out at 40°C and compression rate of 0.01 mm/s using the RSA-G2 instrument (TA Instruments) equipped with parallel plates. Three levels of DCP were used for these measurements, namely, 0.32, 1.0 and 3.2 phr. The compressive stress-strain curves measured during continuous loading-unloading cycles with increasing maximum strains are shown in FIGS. 9A-9C. The plots show that at DCP levels at and above 1 phr, the hysteresis and compressive set are negligible. This indicate that the deformation of the cured ODEDM is completely reversible after very large deformations (>80% strain). Additionally, very strong strain-hardening response is observed when the strain increases above 40%. [0289] FIG.10A shows the maximum stress reached as a function of maximum strain. This plot illustrate the tunability of the tensile strength of elastomers by varying the curative level. It is possible to change the tensile strength in two orders of magnitudes by increasing the DCP from 0.32 to 3.2 phr. FIG.10B shows that the maximum strength follows a power law relation with strain and also shows an upward deviation at strains >40%, which is evidence of the strain- hardening behavior. The significant strain hardening is very desirable self-reinforcing phenomena that allows these polymer to resist high loads without penalty on their physical integrity (compression set). FIG. 10C shows the compressive set and the dissipated energy (Edis), as a function of strain. Edis is a measure of the hysteretic behavior of the elastomers under compression and it is measured as the area between the curves describing loading and unloading cycles in the stress-strain curves. Lowest compressive set is achieved by increasing the DCP level, whereas the hysteresis is less sensitive to the DPC level. [0290] Overall, linear α-olefin-diene copolymers of the present disclosure can have a higher diene content, as compared to conventional diene-containing polymers. The linear α-olefin-diene copolymers can be optionally crosslinked to provide additional control and manipulation of some polymer properties. It has further been discovered that linear α-olefin- diene copolymers of the present disclosure can have low hysteresis and/or low tensile set. Linear α-olefin-diene copolymers may be suitable for use in, for example, a rubber phase of an ICP. The rubber phase can have less (if any) solvent/oil, as compared to conventional ICPs. In addition, solvent/oil that is optionally present in the rubber phase is less prone to being squeezed out during use. Low hysteresis and/or low tensile set may be achieved by linear α- olefin-diene copolymers without sacrificing impact properties, such as strain hardening properties, that allow the polymers to resist high loads and without penalty of their physical integrity for repeated physical impact(s) during real world use. [0291] The phrases, unless otherwise specified, "consists essentially of" and "consisting essentially of" do not exclude the presence of other steps, elements, or materials, whether or not, specifically mentioned in this specification, so long as such steps, elements, or materials, do not affect the basic and novel characteristics of the present disclosure, additionally, they do not exclude impurities and variances normally associated with the elements and materials used. [0292] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, within a range includes every point or individual value between its end points even though not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited. [0293] All documents described herein are incorporated by reference herein, including any priority documents and or testing procedures to the extent they are not inconsistent with this text. As is apparent from the foregoing general description and the specific embodiments, while forms of the present disclosure have been illustrated and described, various modifications can be made without departing from the spirit and scope of the present disclosure. Accordingly, it is not intended that the present disclosure be limited thereby. Likewise, the term “comprising” is considered synonymous with the term “including” for purposes of United States law. Likewise whenever a composition, an element or a group of elements is preceded with the transitional phrase “comprising,” it is understood that we also contemplate the same composition or group of elements with transitional phrases “consisting essentially of,” “consisting of,” “selected from the group of consisting of,” or “is” preceding the recitation of the composition, element, or elements and vice versa. [0294] While the present disclosure has been described with respect to a number of embodiments and examples, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope and spirit of the present disclosure.

Claims

CLAIMS What is claimed is: 1. A copolymer, comprising: about 50 wt% to about 99.9 wt% C6-C60 linear α-olefin units, based on the weight of the copolymer; diene units; and optionally C2-C10 α-olefin comonomer units different than the C6-C60 linear α-olefin units.
2. The copolymer of claim 1, wherein the copolymer comprises ethylene units.
3. The copolymer of any preceding claim, wherein the copolymer comprises about 90 wt% to about 99 wt% C6-C60 linear α-olefin units, based on the weight of the copolymer, and preferably the C6-C60 linear α-olefin comprises a C16–C26 linear α-olefin or the C6-C60 linear α-olefin comprises 1-decene or 1-octadecene.
4. The copolymer of any preceding claim, wherein the copolymer comprises about 1 wt% to about 10 wt%, preferably about 2 wt% to about 5 wt%, diene units, based on the weight of the copolymer.
5. The copolymer of any preceding claim, wherein the diene comprises a C7-C9 diene or is an α,Ω-die.
6. The copolymer of any preceding claim, wherein the diene is selected from the group consisting of vinylnorbornene, norbornadiene, 5-ethylidene-2-norbornene, 5-vinyl-2- norbornene, divinylbenzene, dicyclopentadiene, and combination(s) thereof.
7. The copolymer of any preceding claim, wherein the copolymer comprises about 1.5 wt% to about 2.5 wt% or about 8 wt% to about 12 wt% ethylene units, based on the weight of the copolymer.
8. The copolymer of any preceding claim, wherein the copolymer has an Mw value of about 100,000 g/mol to about 500,000 g/mol, preferably about 200,000 g/mol to about 300,000 g/mol, and more preferably about 70,000 g/mol to about 200,000 g/mol.
9. The copolymer of any preceding claim, wherein the copolymer has an Mw/Mn value from 1 to 5, preferably from 2 to 3.
10. The copolymer of any preceding claim, wherein the copolymer has a glass transition temperature (Tg) of about -50°C to about -70°C and a crystallization temperature (Tc) of about 60°C to about 80°C.
11. A crosslinked copolymer having the following properties: a tensile set @200% deformation of about 0.1% to about 50% or less, preferably of about 3% to about 7%; a tensile strength at 40°C of about 50 kPa to about 1,000 kPa, preferably of about 400 kPa to about 650 kPa; an Edis of about 1 kJ/m3 to about 10 kJ/m3; an elongation at break of about 10% to about 1,000%, preferably of about 400% to about 500%, and more preferably of about 150% to about 250%; a Young’s modulus (at 40°C) of about 50 kPa to about 1,000 kPa, preferably about 500 kPa to about 600 kPa; a glass transition temperature (Tg) of about –100°C to about 0°C, preferably about –70°C to about –60°C; a melting temperature (Tm) of about 50°C to about 150°C, preferably about 90°C to about 110°C, and more preferably about 110°C to about 135°C ; and a temperature of crystallization (Tc) of about 10°C to about 150°C, preferably about 60°C to about 80°C, and more preferably about 10°C to about 35°C.
12. An impact copolymer, comprising: from 10 wt% to 80 wt% of the copolymer of claim 1 or claim 11, based on the weight of the impact copolymer; and a polypropylene, wherein the impact copolymer comprises: a continuous phase comprising the polypropylene; and a dispersed phase comprising the copolymer, wherein the dispersed phase comprises less than 5 wt% polypropylene, based on the weight of the dispersed phase.
13. The impact copolymer of claim 12, wherein the impact copolymer has a compressive strength at 23°C of about 100 MPa to about 500 MPa.
14. The impact copolymer of any one of claims 12-13, wherein the impact copolymer is free of oil, or has less than 150 phr oil, or has less than 25 phr oil, or has 0 phr oil.
15. A process, comprising: introducing a C6-C60 linear α-olefin, a diene, and optionally C2-C10 α-olefin comonomer (different than the C6-C60 linear α-olefin) to a catalyst system comprising an activator and a tetrahydroindacenyl catalyst compound; and producing, under reaction conditions, the copolymer of claim 1 or claim 22, wherein the reaction conditions comprise a temperature of about 0°C to about 300°C, a pressure of about 0.35 MPa to about 16 MPa, and a time up to about 300 minutes, wherein the tetrahydroindacenyl catalyst compound is µ-(CH3)2Si(η5-2,6,6-trimethyl-1,5,6,7-tetrahydro-s- indacen-1-yl)(tertbutylamido)M(R)2, wherein M is selected from the group consisting of Ti, Zr, and Hf, and R is selected from the group consisting of halogen and C1 to C5 alkyl.
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