Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
  • C08F290/02—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups on to polymers modified by introduction of unsaturated end groups
  • C08F290/04—Polymers provided for in subclasses C08C or C08F
  • C08F290/042—Polymers of hydrocarbons as defined in group C08F10/00
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F110/04—Monomers containing three or four carbon atoms
  • C08F110/06—Propene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F210/04—Monomers containing three or four carbon atoms
  • C08F210/06—Propene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F255/00—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00
  • C08F255/02—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00 on to polymers of olefins having two or three carbon atoms
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L55/00—Compositions of homopolymers or copolymers, obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in groups C08L23/00 - C08L53/00
  • C08L55/005—Homopolymers or copolymers obtained by polymerisation of macromolecular compounds terminated by a carbon-to-carbon double bond
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F2420/00—Metallocene catalysts
  • C08F2420/02—Cp or analog bridged to a non-Cp X anionic donor
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; 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
  • C08F4/60—Metals; 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
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
  • C08F4/65908—Component 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+
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; 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
  • C08F4/60—Metals; 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
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
  • C08F4/65912—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an organoaluminium compound

Definitions

• the present invention relates to comb-block polyolefins useful as modifiers in linear polyolefin compositions and in hydrocarbon fluids and methods of making them, and in particular to atactic polypropylene comb-block poly ethylenes and poly propylenes.
• Linear polyolefins that must be processed by melt extrusion such as high density polyethylene (HDPE), linear low density polyethylene (LLDPE), and isotactic polypropylene (iPP) do not exhibit extensional flow hardening, which is a critical property for film blowing, thermoforming, extrusion casting, and foaming.
• a processability "modifier” such as a long chain branched polyolefin can be added in small amounts to linear polyolefins to provide extensional hardening.
• LDPE high pressure low density polyethylene
• long chain branched polyolefins have lower toughness and their addition often compromises the mechanical properties of the linear polyolefins to which they are added.
• LDPE its uses have been limited to be 20 wt% or less of the overall composition but even at 5 wt% addition the impact strength of a LLDPE would drop by 50%.
• LDPE Due to heterogeneous branch types present in the LDPE with ineffective star branches diluting the more effective dendritic branches, a large amount, greater than 5%, of LDPE is necessary to have any processability benefits. It is desirable to use effective long chain branched polyolefins at an amount of 5% or less that can deliver extensional flow hardening but without compromising mechanical properties.
• Long chain branched viscosity modifiers are beneficial for shear thinning and for fuel economy, and there are multi-arm star polyolefin materials presently in the market place based on poly(hydrogenated isoprene-co-styrene) copolymers with hydrogenated polyisoprene having star arms of 20 to 40 centered on a cross-linked polystyrene core.
• These long chain branches deliver earlier shear thinning onset in a hydrocarbon base stock for lower viscosity at high shear rates and better fuel economy.
• their thickening efficiency is poor due to the coil dimensional shrinkage as a result of long chain branching and they are easily oxidized and degraded as a result of the presence of oxidation-prone polystyrene.
• Poly(ethylene/propylene-b-atactic propylene) comb-block copolymers were synthesized in WO 2014/120478 to Jiang et al, but having atactic polypropylene combs having a weight average molecular weight of less than 5,500 g/mole in the examples of that patent publication, which is too short for ideal flow hardening.
• atactic polypropylene comb- block polyolefins having combs (or "comb blocks") with a weight average molecular weights greater than 8,000 g/mole, greater than the entanglement weight average molecular weight of atactic propylene which is 7,000 g/mole.
• the proper comb length imparts the extensional flow hardening when the comb block is used as a processability modifier in linear PE, in PP, or PE/PP blend matrix. This longer comb length also expands the solution coil dimensions allowing its use as a viscosity modifier in liquid hydrocarbons or polyolefins.
• a process for preparing atactic polypropylene comb-block polyolefins comprising contacting, at a temperature within a range from 20 to 55 or 60 or 65 or 70°C, propylene with a first metallocene precursor and an activator to form vinyl-terminated atactic polypropylene having a weight average molecular weight of at least 8000 or 10,000 g/mole and a crystallinity of less than 20 or 10 or 5%; and contacting, at a temperature within a range from 40 to 55 or 60 or 70 or 90 or 130 or 150°C, the vinyl-terminated atactic polypropylene with ethylene, propylene, or both, a second metallocene precursor, and an activator to form atactic polypropylene comb-block polyolefins.
• atactic polypropylene comb-block polyolefin comprising two blocks: a polyolefin backbone; and atactic polypropylene combs pendant to the backbone having a weight average molecular weight of at least 8,000, or 10,000 g/mole and a crystallinity of less than 20 or 10 or 5%; wherein the atactic polypropylene comb-block polyolefin has a comb number of at least 2 or 4 or 6 or 10.
• FIG. 1 is a Van Gurp-Palmen plot of various inventive atactic polypropylene comb-block polyolefins, which is a plot of the phase angle (tangent angle corresponding to the ratio of shear loss modulus to shear storage modulus) plotted against complex shear modulus.
• FIG. 2 is a Carreau Yasada plot for inventive atactic polypropylene comb-block poly olefins and comparative viscosity modifiers which is a plot of the viscosity as a function of shear rates.
• FIG. 3 is a GPC plot of an inventive processability atactic polypropylene comb- block poly olefins ("modifier 1") where the peak to the left (low molecular weights) represents the linear low molecular weight component (LLMW) and the second peak (at high molecular weights) represents the atactic polypropylene comb-block polyethylene.
• modifier 1 an inventive processability atactic polypropylene comb- block poly olefins
• FIG. 4 is a GPC plot of the inventive modifier 1 showing the corrected long chain branch index, g', corrected for the propylene content (presence of short chain branches, methyl from propylene comonomer).
• FIG. 5 is a time-temperature dependent plots of the storage and loss modulus as a function of angular frequency demonstrating thermo-rheological complex due to the combed- block nature of modifier 1.
• FIG. 6 is a time-temperature dependent plots of the storage and loss modulus as a function of angular frequency demonstrating thermo-rheological complex due to the combed- block nature of modifier 2.
• FIG. 7 is a plot of Modulus as a function of shear rate to demonstrate extensional flow hardening of a 50/50 polyethylene/polypropylene blend containing 5% modifier 1 at 190°C.
• an atactic polypropylene comb- block polyolefin comprising two covalently bound blocks comprising a polyolefin backbone, and atactic polypropylene branches or "combs" pendant to the backbone having a weight average molecular weight of at least 8,000 or 10,000 g/mole and a crystallinity of less than 20 or 10 or 5%, and wherein the atactic polypropylene comb-block polyolefin has comb number
• number of branches pendant to the backbone polyolefin of at least 2 or 4 or 6 or 10.
• a vinyl-terminated atactic polypropylene is generated, followed by incorporation of that vinyl-terminated atactic polypropylene into a forming polyolefin backbone, either polypropylene having branches derived from the vinyl-terminated atactic polypropylene or polyethylene having branches derived from the vinyl-terminated atactic polypropylene, the whole structure referred to as a "comb" structure.
• a process for preparing the atactic polypropylene comb- block polyolefins comprising contacting, at a temperature within a range from 20 to 55 or 60 or 65 or 70°C of propylene with a first metallocene precursor and an activator to form vinyl- terminated atactic polypropylene having a weight average molecular weight of at least 8,000 or 10,000 g/mole and a crystallinity of less than 20 or 10 or 5%; and contacting, at a temperature within a range from 40 to 55 or 60 or 70 or 90 or 130 or 150°C, the vinyl- terminated atactic polypropylene with ethylene, propylene, or both, a second metallocene precursor, and an activator to form atactic polypropylene comb-block polyolefins.
• the "contacting" may occur as two steps together in one reactor, in two separate zones in one reactor, or in separate reactors such as in series reactors.
• the crystallinity of the vinyl-terminated atactic polypropylenes (and the combs pendant to the polyolefin backbone by inference) used to make the inventive comb block polyolefins described herein are measured using Differential Scanning Calorimetry (DSC) using commercially available equipment such as a TA Instruments 2920 DSC.
• DSC Differential Scanning Calorimetry
• 6 to 10 mg of the sample, that has been stored at 25°C for at least 48 hours, is sealed in an aluminum pan and loaded into the instrument at 25°C.
• the sample is equilibrated at 25°C, then it is cooled at a cooling rate of 10°C/min to -80°C, to obtain heat of crystallization (Tc).
• the endothermic melting transition if present, is analyzed for onset of transition and peak temperature.
• the heats of melting, AH m , and cold crystallization, ⁇ ⁇ are determined by integrating the areas (J/g) under the peaks. Depending upon the sample's given thermal history, a cold crystallization exothermic peak may or may not be observed during the DSC experiment.
• the heats of melting and cold crystallization are in terms of J/g.
• the term AH m is a reference value and represents the heat of melting if the polymer were 100% crystalline. This reference heat of melting has been established for each of the commonly used polymers, and for polypropylene the AH m is 207.1 J/g.
• the inventive process takes place in two steps or stages, each step/stage preferably requiring a different metallocene catalyst precursor.
• the first and second contacting steps take place in the same reactor, but at different times.
• a first metallocene is used in a first contacting stage or step until the polymerization reaction has run for a desired amount of time, followed by addition of a second metallocene catalyst in a second step.
• the first contacting may take place in a different reactor than the second contacting stage or step, such as in serial reactors where the reaction effluent from the first reactor is transferred to the second reactor, at least in part or whole, in a continuous process.
• a first metallocene can be added to the first reactor, followed by addition of a second metallocene to a second reactor along with the effluent from the first reactor.
• These polymerization steps take place at different temperatures as indicated above, and may take place at the same or different pressures, preferably a pressure of at least 1 or 2 MPa, or within a range from 1 or 2 MPa to 4 or 6 or 8 MPa.
• the first stage is preferably the stage in which a vinyl-terminated atactic polypropylene is formed and thus a first metallocene that favors the formation of vinyl-terminated atactic polypropylenes is desirable.
• the first metallocene precursor is selected from the group consisting of bridged C2 symmetric hafnocenes and zirconocenes; preferably symmetrically CI to C6 alkyl substituted.
• the first metallocene (and/or second metallocene) is selected from those having the following structure, especially desirable for producing atactic polypropylene or isotactic polypropylene, depending upon the substitution partem on the indenyl ring(s):
• M is a Group 4 (titanium, zirconium, hafnium) metal, preferably Zr or Hf, most preferably Hf;
• each X is independently a halogen or CI to CIO alkyl, or C6 to CIO aryl;
• A is a methylene or ethylene, wherein the ethylene has two R 1 groups on each carbon, or "A” is a silane;
• each R 1 is independently selected from hydrogens, CI to CIO alkyls, and C6 to CIO aryls; each of R 2 to R 7 is independently selected from hydrogens, CI to CIO alkyls, C6 to CIO aryls, C7 to C24 alkylaryls, and C7 to C24 arylalkyls;
• each of R 5 to R 7 are hydrogen, R 2 is a CI to C4 alkyl, and R 3 is a C2 to C6 alkyl; and
• R 2 and R 3 may form a C4 to C7 saturated or unsaturated ring.
• the second stage or step of the process is, preferably, one in which a backbone polyolefin is formed in the presence of the reactor effluent of the first stage or step, which contains vinyl-terminated atactic polypropylene.
• the second metallocene catalyst is chosen that favors the incorporation of vinyl-terminated polyolefins as a monomer unit while forming the backbone polyolefin.
• the second metallocene precursor is selected from C s symmetric bis-cyclopentadienyl Group 4 complexes, C2 symmetric bis-cyclopentadienyl Group 4 complexes, and mono-cyclopentadienyl Group 4 complexes.
• the second metallocene precursor may be selected from those having the following structure, especially when syndiotactic polypropylene or polyethylene is desired for the backbone polyolefin:
• M is a Group 4 metal, preferably Zr or Hf;
• each X is independently a halogen or CI to CIO alkyl, or C6 to CIO aryl;
• A is a methylene or ethylene, wherein the ethylene has two R 1 groups on each carbon, or
• A is a silane
• each R 1 is independently selected from hydrogens, CI to CIO alkyls, and C6 to CIO aryls; each of R 2 to R 13 is independently selected from hydrogens, CI to CIO alkyls, C6 to CIO aryls, C7 to C24 alkylaryls, and C7 to C24 arylalkyls; preferably each of R 3 and R 8 are a C2 to C6 iso- or tert-alkyls, and the other R groups are hydrogen; and
• R 2 and R 3 may form a C4 to C7 saturated or unsaturated ring.
• the second metallocene precursor may, preferably, be selected from those having the following structure, especially when atactic polypropylene is desired for the backbone poly olefin:
• M is a Group 4 metal, preferably Ti
• each X is independently a halogen or CI to CIO alkyl, or C6 to CIO aryl;
• A is a methylene or ethylene, wherein the ethylene has two R 1 groups on each carbon, or "A” is a silane;
• Q is a heteroatom or hydrocarbon group
• n 1, 2, or 3;
• each R 1 is independently selected from hydrogen, CI to CIO alkyls, and C6 to CIO aryls; each of R 2 to R 5 is independently selected from hydrogens, CI to CIO alkyls, C6 to CIO aryls, C7 to C24 alkylaryls, and C7 to C24 arylalkyls; and
• R 6 is selected from CI to CIO alkyls, and C4 to C20 saturated or unsaturated rings.
• the "activator” comprises any compound capable of converting the catalyst precursor into an active polymerization catalyst, and preferably includes alkyl alumoxane compounds (e.g., methylalumoxane) and/or tetra(perfluorinated aromatic)borates, but more preferably comprises tetra(perfluorinated aromatic)borates. Even more preferably, the activator comprises anions selected from tetra(pentafluorophenyl)borate, tetra(perfluorobiphenyl)borate, tetra(perfluoronaphthyl)borate, and combinations thereof. In the case of anionic activators, the activator also comprises a bulky organic cation (trialkyl ammonium, trialkylmethyl), preferably dialkylanilinium cation, or triphenylmethyl cation.
• alkyl alumoxane compounds e.g., methylalumoxane
• the inventive process further comprises forming a linear low molecular weight component (LLMW) in the second step comprising ethylene or ethylene/propylene copolymers and having a number average molecular weight within a range from 7,000 to 50,000 g/mole.
• LLMW linear low molecular weight component
• the atactic polypropylene comb-block polyolefins formed herein may be a composition that also includes the LLMW in as much as 2 or 4 or 6 wt% to 10 or 20 wt%.
• the atactic polypropylene comb-block polyolefins are block copolymers comprising atactic polypropylene block(s) and a poly olefin block.
• the atactic polypropylene blocks are essentially branches pendant to the polyolefin backbone, thus having a "comb" structure.
• the inventive structures have comb number (number of branches pendant to the backbone polyolefin) of 2 or 4 or 6 or 10 or more; or within a range from 2 or 4 or 6 or 10 to 20 or 24 or 28 or 32.
• the atactic polypropylene comb-block polyolefin (preferably polyethylene) exhibits a CH branching number (mol%, 1 C NMR) greater than 1 or 1.5 or 2, or within a range from 1 or 1.5 or 2 to 7 or 9 or 12 or 15.
• the GPC of the atactic polypropylene comb-block polyolefins exhibits bimodal molecular weight distribution, most preferably when serial reactors are used to make the comb-block structures.
• the "backbone" polyolefin block is a polyethylene or polypropylene; more preferably selected from isotactic polypropylenes, a syndiotactic polypropylenes, ethylene-propylene copolymers, polyethylenes (HDPE or LLDPE), and combinations thereof.
• the atactic polypropylene comb-block polyolefin has a weight average molecular weight (Mw) within the range from 100,000 or 200,000 or 250,000 g/mole to 300,000 or 500,000 or 750,000 or 900,000 g/mole, preferably when serial reactors are used to make the comb-block structures.
• the atactic polypropylene comb- block polyolefins has a number average molecular weight (Mn) within the range from 4,000 or 6,000 or 7,000 g/mole to 20,000 or 30,000 or 40,000 or 50,000 g/mole, preferably when serial reactors are used to make the comb-block structures.
• the atactic polypropylene comb-block polyolefins has a z-average molecular weight (Mz) of greater than 500,000 or 750,000 or 900,000 g/mole, or within a range from 500,000 or 750,000 or 900,000 g/mole to 1,500,000 or 2,000,000, or 2,500,000 g/mole, preferably when serial reactors are used to make the comb-block structures.
• Mz z-average molecular weight
• the atactic polypropylene comb-block polyolefins preferably have a molecular weight distribution (Mw/Mn) greater than 10 or 30 or 50, or within a range from 10 or 30 or 50 to 100 or 140 or 160, preferably when serial reactors are used to make the comb-block structures.
• the inventive atactic polypropylene comb-block polyolefin has a number of uses as a modifier present within the range from 0.05 or 0.1 or 0.5 wt% to 7 or 10 or 15 wt% of the composition in either polyolefin compositions, especially polypropylenes, polyethylenes, and blends containing polypropylene and polyethylene, where it acts as a modifier to improve the processability and performance of the composition.
• the inventive atactic polypropylene comb-block polyolefin is useful as a modifying additive in hydrocarbon fluids such as motor oils, where they are demonstrated herein to improve high temperature viscosity of such fluids.
• Molecular weights (number average molecular weight (Mn), weight average molecular weight (Mw), and z-average molecular weight (Mz)) were determined using a Polymer Laboratories Model 220 high temperature GPC-SEC equipped with on-line differential refractive index (DRI), light scattering (LS), and viscometer (VIS) detectors (so called GPC-3D, Gel Permeation Chromatography -3 Detectors). It used three Polymer Laboratories PLgel 10 m Mixed-B columns for separation using a flow rate of 0.54 ml/min and a nominal injection volume of 300 ⁇ . The detectors and columns were contained in an oven maintained at 135°C.
• DRI differential refractive index
• LS light scattering
• VIS viscometer
• the stream emerging from the size exclusion chromatography (SEC) columns was directed into the miniDAWN (Wyatt Technology, Inc.) optical flow cell and then into the DRI detector, or IR detector for the data in FIGs. 3 and 4.
• the DRI detector was an integral part of the Polymer Laboratories SEC.
• the viscometer was inside the SEC oven, positioned after the DRI detector. The details of these detectors, as well as their calibrations, have been described by, for example, T. Sun, P. Brant, R. R. Chance, and W. W. Graessley, in 34(19) MACROMOLECULES, 6812-6820, (2001).
• GPC-IR is a high temperature Gel Permeation Chromatograph or Size Exclusion Chromatograph (GPC/SEC) with an infrared detector, a built-in viscometer and a Multi- Angle Light Scattering (DAWNTM HELEOSTM II 8 or 18 angle of Wyatt Technology). This is also called GPC-4D, four detectors, since infrared detector measures both the concentration and composition. Counting concentration, composition, along with the viscosity from viscometer and the coil dimension from MALS (multi-angle light scattering), there are four parameters being measured using GPC-IR, hence, GPC-4D.
• Solvent for the GPC-SEC was prepared by dissolving 6 grams of butylated hydroxy toluene as an antioxidant in 4 liters of Aldrich reagent grade 1 ,2,4-trichlorobenzene (TCB). The TCB mixture was then filtered through a 0.7 ⁇ glass pre-filter and subsequently through a 0.1 ⁇ Teflon filter. The TCB was then degassed with an online degasser before entering the SEC. Polymer solutions were prepared by placing dry polymer in a glass container, adding the desired amount of TCB, then heating the mixture at 160°C with continuous agitation for 2 hours. All quantities were measured gravimetrically.
• the TCB densities used to express the polymer concentration in mass/volume units were 1.463 g/mL at room temperature and 1.324 g/mL at 135°C.
• the injection concentration was from 1.0 to 2.0 mg/mL, with lower concentrations being used for higher molecular weight samples.
• Prior to running each sample the DRI detector and the injector were purged. Flow rate in the apparatus was then increased to 0.5 mL/minute, and the DRI was allowed to stabilize for 8 to 9 hours before injecting the first sample.
• the concentration, c, at each point in the chromatogram was calculated from the baseline-subtracted DRI signal, IDRJ, using the following equation:
• KTJRJ is a constant determined by calibrating the DRI
• (dn/dc) is the refractive index increment for the system.
• (dn/dc) 0.104 for propylene polymers and 0.1 otherwise.
• Units of parameters used throughout this description of the SEC method are: concentration is expressed in g/cm ⁇ , molecular weight is expressed in g/mol, and intrinsic viscosity is expressed in dL/g.
• the light scattering detector was a high temperature miniDAWN (Wyatt Technology, Inc.).
• the primary components are an optical flow cell, a 30 mW, 690 nm laser diode light source, and an array of three photodiodes placed at collection angles of 45°, 90°, and 135°.
• the molecular weight, M, at each point in the chromatogram was determined by analyzing the LS output using the Zimm model for static light scattering (M.B. Huglin, LIGHT SCATTERING FROM POLYMER SOLUTIONS Academic Press, 1971):
• AR(6) is the measured excess Rayleigh scattering intensity at scattering angle ⁇
• c is the polymer concentration determined from the DRI analysis
• (dn/dc) 0.104 for propylene polymers, 0.098 for butene polymers and 0.1 otherwise
• ⁇ ( ⁇ ) is the form factor for a monodisperse random coil
• K 0 is the optical constant for the system:
• a high temperature viscometer from Viscotek Corporation was used to determine specific viscosity.
• the viscometer has four capillaries arranged in a Wheatstone bridge configuration with two pressure transducers. 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, ⁇ 8 for the solution flowing through the viscometer was calculated from their outputs.
• the intrinsic viscosity, [ ⁇ ] at each point in the chromatogram was calculated from the following equation:
• the branching index (g' v is) i s defined as the ratio of the intrinsic viscosity of the branched polymer to the intrinsic viscosity of a linear polymer of equal molecular weight and same composition, and was calculated using the output of the SEC-DRI-LS-VIS method as follows.
• ] a vg > °f me sample was calculated by:
• the branching index g' v i s is defined as:
• Viscosity was measured using a Brookfield Viscometer according to ASTM D- 3236.
• Mn (1H NMR) was determined according to the following NMR method. 1H NMR data is collected at either room temperature or 120°C (for purposes of the claims, 120°C shall be used) in a 5 mm probe using a Varian spectrometer with a 1H frequency of 250 MHz, 400 MHz, or 500 MHz (for the purpose of the claims, a proton frequency of 400 MHz is used). Data were recorded using a maximum pulse width of 45°C, 8 seconds between pulses and signal averaging 120 transients. Spectral signals were integrated and the number of unsaturation types per 1000 carbons was calculated by multiplying the different groups by 1000 and dividing the result by the total number of carbons. Mn is calculated by dividing the total number of unsaturated species into 14,000, and has units of g/mol.
• samples were prepared by adding 0.3 g sample to approximately 3 g of tetrachloroethane-d2 in a 10 mm NMR tube. The samples were dissolved and homogenized by heating the tube and its contents to 150°C. The data were collected using a Varian spectrometer, with corresponding 1H frequencies of either 400 or 700 MHz (in event of conflict, 700 MHz shall be used). The data were acquired using nominally 4000 transients per data file with a 10 second pulse repetition delay. To achieve maximum signal-to-noise for quantitative analysis, multiple data files were added together.
• the spectral width was adjusted to include all the NMR resonances of interest and FIDs were collected containing a minimum of 32K data points.
• the samples were analyzed at 120°C in a 10 mm broad band probe.
• T ⁇ Melting temperature
• DSC Differential Scanning Calorimetry
• 6 to 10 mg of the sample, that has been stored at room temperature for at least 48 hours, is sealed in an aluminum pan and loaded into the instrument at room temperature.
• the sample is equilibrated at 25°C, then it is cooled at a cooling rate of 10°C/min to -80°C, to obtain heat of crystallization (Tc).
• the sample is held at -80°C for 5 min and then heated at a heating rate of 10°C/min to 25°C.
• the glass transition temperature (Tg) is measured from the heating cycle.
• the sample is equilibrated at 25°C, then heated at a heating rate of 10°C/min to 150°C.
• the endothermic melting transition if present, is analyzed for onset of transition and peak temperature.
• the melting temperatures reported (T ⁇ ) are the peak melting temperatures from the second heat unless otherwise specified.
• the melting point or melting temperature is defined to be the peak melting temperature (i.e., associated with the largest endothermic calorimetric response in that range of temperatures) from the DSC melting trace.
• the T ⁇ is measured to within ⁇ 0.2°C.
• Propylene was added to the reactor.
• the reactor was sealed and heated.
• the catalyst solution (catalyst precursor and activator dissolved in toluene) was added to the reactor. Polymerization began immediately upon addition of the catalyst, and was allowed to continue under controlled temperature for the indicated times.
• the second stage was completed by adding a solution of the second catalyst/activator as shown in Table IB. After the indicated time, the reactor was allowed to reach room temperature and depressurized by venting.
• the polymerization solution was poured into an aluminum tray. The polymer was collected and allowed to dry over 16 h under ambient condition. The polymer was dried further under vacuum at 60°C.
• sPP Polypropylene containing sydiotactic propylene sequences
• iPP Polypropylene containing isotactic propylene sequences
• the Van Gurp-Palmen plot is a plot of measured phase angle (tangent angle corresponding to the ratio of shear loss modulus to shear storage modulus) plotted against complex shear modulus.
• Sample 1 has the linear polymer characteristic of a smooth curved-down shape.
• phase angle at a given shear modulus would be found.
• the lower the phase angle at 10,000 Pa complex modulus suggests more branches (or more complex branches).
• Blending experiments were carried out using a polyalphaolefin (4 centipoise viscosity, 25°C) as the base stock to study the viscosity shift versus the shear rate.
• a polyalphaolefin (4 centipoise viscosity, 25°C) as the base stock to study the viscosity shift versus the shear rate.
• an ultra-high shear viscometer (shear rate range from 10 6 to 10 7 1/s)
• a m-VROC micro-capillary viscometer shear rate range from 10 3 to 10 6 1/s
• an ANTON-PAAR rheometer shear rate range from 1 to 10 3 1/s
• time-temperature superposition was then applied to consolidate all measured data into one single viscosity master curve at a reference temperature of 100°C using shift factors.
• TTS time-temperature superposition
• the purification system consisted of an Oxiclear column (model RGP-R1-500 from Labclear) followed by a 5A and a 3A molecular sieve column. Purification columns were regenerated periodically whenever there was evidence of lower activity of polymerization. Both the 3A and 5A molecular sieve columns were regenerated in-house under nitrogen at a set temperature of 260°C and 315°C, respectively. The molecular sieve material was purchased from Aldrich. The Oxiclear column was regenerated as described by the manufacture. Ethylene was delivered as a gas solubilized in the chilled solvent/monomer mixture.
• the purified solvents and monomers were then chilled to about -15°C by passing through a chiller before being fed into the reactors through a manifold. Solvent and monomers were mixed in the manifold and fed into reactor through a single tube. Catalyst and monomer contacts took place in the reactor. All liquid flow rates were measured using Brooksfield mass flow controllers.
• the reactors were first prepared by continuously N 2 purging at a maximum allowed temperature, then pumping isohexane and scavenger solution through the reactor system for at least one hour. Monomers and catalyst solutions were then fed into the reactor for polymerization. Once the activity was established and the system reached equilibrium, the reactor was lined out by continuing operation of the system under the established condition for a time period of at least five times of mean residence time prior to sample collection. The resulting mixture, containing mostly solvent, polymer and unreacted monomers, was collected in a collection box.
• the collected sample modifiers were washed with xylene to remove unreacted macromonomers, and then air-dried in a hood to evaporate most of the solvent followed by drying in a vacuum oven at a temperature of about 90°C for about 12 hours.
• the vacuum oven dried sample modifiers were weighed to obtain yields. All the reactions were carried out at a gauge pressure of about 2.4 MPa.
• the catalyst used in the first reactor for the production of vinyl-terminated polypropylene was rac-dimethylsilyl bis(2-methyl-3-propyl-indenyl) hafnium dimethyl (Catalyst 1) and the activator was N,N-dimethylanilinium tetrakis(heptafluoro-2-naphthyl) borate.
• the catalyst used in the second reactor to copolymerize ethylene and vinyl- terminated polypropylene was p-triethylsilylphenylcarbyl bis(cyclopentadienyl)(2,7-di-t- butylfluorenyl) hafnium dimethyl (Catalyst 2) activated by dimethylanilinium tetrakis(pentafluorophenyl) borate. A small amount of propylene was carried over to the second reactor. Both catalysts were pre-activated with the activator at a molar ratio of about 1 : 1 in 900 ml of toluene. All catalyst solutions were kept in an inert atmosphere and fed into reactors using an ISCO syringe pump.
• Tri-n-octylaluminum (TNOAL) solution (available from Sigma Aldrich, Milwaukee, WI) was further diluted in isohexane and used as a scavenger. Scavenger feed rate was adjusted to maximize the catalyst efficiency.
• the molecular weight, as measured by proton NMR and by GPC-3D, of the vinyl- terminated atactic polypropylene from the first reactor exceeds the target weight average molecular weight of 8,000 or 10,000 g/mole which satisfies the requirement of greater than the entanglement molecular weight of atactic polypropylene of 7,050 g/mole (see 31(4) MACROMOLECULES, 1335-1340 (1998)).
• Table 2A Polymerization Conditions for Process Modifier Example and Results
• Time-temperature superposition failed on Modifiers 1 and 2 since they are thermo-rheological complex due to their combed-block nature.
• Time- Temperature superposition derived from time-temperature correspondence principle (Aklonis, J. J., and MacKnight, W. J., "Introduction to Polymer Viscoelasticity", 2nd ed., John Wiley and Sons, New York, (1983), Chapter 3), should be applicable to all polymers, linear and branched, of homogeneous compositions.
• the propylene content in the backbone of Modifier 1 may be estimated to be around 5 to 10 wt%.
• the comb block structure in Modifier 1 has 17 combs (branches originating from the polyethylene backbone) and with a weight average molecular weight of 42,000 g/mole in between combs.
• a process for preparing atactic polypropylene comb-block poly olefins comprising (or consisting essentially of, or consisting of) contacting, at a temperature within a range from 20 to 55 or 60 or 65 or 70°C, propylene with a first metallocene precursor and an activator to form vinyl-terminated atactic polypropylene having a weight average molecular weight of at least 8000 or 10,000 g/mole and a crystallinity of less than 20 or 10 or 5%; and contacting, at a temperature within a range from 40 to 55 or 60 or 70 or 90 or 130 or 150°C, the vinyl- terminated atactic polypropylene with ethylene, propylene, or both, a second metallocene precursor, and an activator to form atactic polypropylene comb-block poly olefins.
• the first metallocene precursor is selected from the group consisting of bridged C2 symmetric hafnocenes and zirconocenes; preferably symmetrically CI to C6 alkyl substituted.
• atactic polypropylene comb- block polyolefin is an atactic polypropylene comb-block polypropylene having a weight average molecular weight within the range from 50,000 to 500,000 g/mole.
• atactic polypropylene comb-block polyolefin is an atactic polypropylene comb-block polyethylene having a weight average molecular weight within the range from 100,000 to 5,000,000 g/mole.
• LLMW linear low molecular weight component
• PI 1 The process of any one of the previous numbered paragraphs, wherein (preferably when serial reactors are used) the atactic polypropylene comb-block polyolefins has a molecular weight distribution (Mw/Mn) greater than 10 or 30 or 50, or within a range from 10 or 30 or 50 to 100 or 140 or 160.
• Mw/Mn molecular weight distribution
• atactic polypropylene comb-block polyolefin preferably polyethylene
• exhibits a CH branching number greater than 1 or 1.5 or 2, or within a range from 1 or 1.5 or 2 to 7 or 9 or 12 or 15.
• M is a Group 4 metal, preferably Zr or Hf; each X is independently a halogen or CI to CIO alkyl, or C6 to CIO aryl; "A" is a methylene or ethylene, wherein the ethylene has two R 1 groups on each carbon, or "A” is a silane; each R 1 is independently selected from hydrogens, CI to CIO alkyls, and C6 to CIO aryls; each of R 2 to R 13 is independently selected from hydrogens, CI to CIO alkyls, C6 to CIO aryls, C7 to C24 alkylaryls, and C7 to C24 arylalkyls; preferably each of R 3 and R 8 are a C2 to C6 iso- or tert-alkyls, and the other R groups are hydrogen; andwherein R 2 and R 3 may form a C4 to C7 saturated or unsaturated ring.
• M is a Group 4 metal, preferably Ti; each X is independently a halogen or CI to CIO alkyl, or C6 to CIO aryl; "A” is a methylene or ethylene, wherein the ethylene has two R 1 groups on each carbon, or "A” is a silane; Q is a heteroatom or hydrocarbon group; preferably a carbon, nitrogen, silicon, or phosphorous; wherein "n” is 1, 2, or 3; each R 1 is independently selected from hydrogen, CI to CIO alkyls, and C6 to CIO aryls; each of R 2 to R 5 is independently selected from hydrogens, CI to CIO alkyls, C6 to CIO aryls, C7 to C24 alkylaryls, and C7 to C24 arylalkyls; and wherein R 6 is selected from CI to CIO alkyls, and C4 to C20 saturated or unsaturated rings.
• each X is independently a halogen or CI to CIO
• PI 7 The process of any one of the previous numbered paragraphs, wherein at least the first contacting (or stage or step) takes place at a pressure of at least 1 or 2 MPa, or within a range from 1 or 2 MPa to 4 or 6 or 8 MPa.
• PI 8 The process of any one of the previous numbered paragraphs, wherein the activator is a tetra(perfluorinated aromatic)borate.
• An atactic polypropylene comb-block polyolefin comprising two blocks (or components): a polyolefin backbone; and one or more (preferably two or more) atactic polypropylene combs pendant to the backbone having a weight average molecular weight of at least 8,000, or 10,000 g/mole and a crystallinity of less than 20 or 10 or 5%; wherein the atactic polypropylene comb-block polyolefin has a comb number of at least 2 or 4 or 6 or 10. P20.
• Mw/Mn molecular weight distribution
• a modifier for a hydrocarbon fluid or polyolefin composition comprising within the range from 0.05 wt% to 15 wt% of the atactic polypropylene comb-block polypropylene of any one of the previous numbered paragraphs.
• P27 A modifier for polyethylenes and polypropylenes and their blends comprising within the range from 0.05 wt% to 15 wt% of the atactic polypropylene comb-block polyethylene of any one of the previous numbered paragraphs.
• Also claimed, is the use of an atactic polypropylene comb-block polyolefins in a hydrocarbon fluid or a polyolefin composition.

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• 2016
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