MXPA94000838A - Viscosity modifier polymers - Google Patents

Viscosity modifier polymers

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Publication number
MXPA94000838A
MXPA94000838A MXPA/A/1994/000838A MX9400838A MXPA94000838A MX PA94000838 A MXPA94000838 A MX PA94000838A MX 9400838 A MX9400838 A MX 9400838A MX PA94000838 A MXPA94000838 A MX PA94000838A
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ethylene
copolymer
weight
composition
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MXPA/A/1994/000838A
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Spanish (es)
Inventor
Joseph Struglinski Mark
William Ver Strate Gary
Alfredo Bloch Ricardo
Karl West Roger
Eric Johnston John
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Exxon Chemical Patents Inc
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Publication of MXPA94000838A publication Critical patent/MXPA94000838A/en

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Abstract

The invention relates to novel copolymers of alpha-olefins. More specifically, it relates to novel copolymers of ethylene with other alpha-olefins comprised of segmented copolymer chains with compositions which are intramolecularly heterogeneous and intermolecularly homogeneous, as well as to a process for making these copolymers and their use in tube oil applications.

Description

CONCENTRATED COMPOSITION OF ADDITIVES FOR LUBRICATING OILS AND INVENTORS: Gary Willia SEE STRATE, Ricardo Alfredo BLOCH, Mark Joseph STRUGLINSKI, John Eric JOHNSTON, and Roger Karl WEST, all of US nationality, located at 28 Bayside Drive, Atlantic Highlands, New Jersey, USA; 1532 Ashbrook Drive, Scotch Plains, New Jersey, E.U.A.; 379 Rolling Knolls Way, Bridgewater, New • «- Jersey, E.U.A .; 639 Dorain Road, Westfield, New Jersey, E.U.A .; and, 109 Montclair Avenue, Montclair, New Jersey, E.U.A. , respectively.
CAUSAHIENT: EXXON CHEMICAL PATENTS INC., A company of United States nationality, located at 1900 East Linden Avenue, Linden, New Jersey 07036-0710, E.U.A.
ABSTRACT The present invention relates to novel alpha-olefin copolymers comprising intramolecularly heterogeneous and intermolecularly homogeneous copolymer chains.
Background of the Invention The present invention relates to novel alpha-olefin copolymers. More specifically, it relates to novel copolymers of ethylene with other alpha-olefins, comprising strings of copolymers segmented with compositions that are intramolecularly heterogeneous and intermolecularly homogeneous, as well as with a process for making these copolymers and their use in applications in Lubricant oils. For convenience, certain terms that are repeated throughout the present description are defined below: a. Inter-CD defines the composition variation, in terms of ethylene content, between polymer chains. It is expressed as the minimum deviation (analogous to a standard deviation) in terms of percentage of ethylene by weight, with respect to the average ethylene composition for a given copolymer sample that is needed to include a given percentage by weight of the sample of total copolymer, which is obtained by excluding fractions of equal weights from both ends of the distribution. The deviation does not need to be symmetric. When expressed as a single number, for example, Inter-CD of 15%, it will mean the largest of the positive or negative deviations. For example, for a Gauss composition distribution, 95.5% of the polymer is within 20% by weight of ethylene of the mean when the standard deviation is 10%. The Inter-CD for 95.5% by weight of the polymer is 20% by weight of ethylene for said sample. b. Intra-CD is the composition variation, in terms of ethylene, within a copolymer chain. It is expressed as the minimum difference in% by weight (p) of ethylene that exists between two portions of a single copolymer chain; each portion comprises at least 5% by weight of the chain. c. Molecular weight distribution (MWD) is a measure of the amplitude of the molecular weights within a given copolymer sample. It is characterized in terms of at least one of the weight average molecular weight ratios with respect to the number average molecular weight, M / Mn and average molecular weight Z with respect to the weight average molecular weight, Mz / M, in which: p S Ni M, 2 S Ni M, Ñn = S Ni M, S Ni Mz = S Ni M, .3 S Ni M, -2 in which Ni is the number of molecular weight molecules M-. d. Viscosity index (I.V.) is the ability of a lubricating oil to accommodate increases in temperature with a minimum decrease in viscosity. The greater this capacity, the higher the I.V. Ethylene-propylene copolymers, pcularly elastomers, are important commercial products and are widely used as viscosity modifiers (MV) in lubricating oils. There is a continuing need to discover polymers with unique properties and compositions for use as viscosity modifiers for lubricating oils. An engine oil should not be too viscous at low temperatures, in order to avoid severe friction losses, facilitate cold stand provide free oil circulation from the stof the engine. On the other hand, should not be too thin at working temperatures, so as to avoid excessive engine wear and excessive oil consumption. It is most desirable to use a lubricating oil that experiences the least change in viscosity with changes in temperature. Polymeric additives have been used extensively in lubricating oil compositions to impart desirable viscosity-temperature characteristics to the compositions. For example, lubricating oil compositions employing ethylene-propylene copolymers (EPM) or ethylene-propylene-non-conjugated diene terpolymers (EPDM) or, more generally, ethylene-alpha-olefin (C3-C18) copolymers , as IV improvers, are well known. These additives are designed to allow the formulation of the lubricant apex, so that changes in viscosity that occur with variations in temperature, remain as small as possible. Lubricating oils containing such polymeric additives tend to maintain their viscosity at an elevated temperature, while maintaining a low viscosity convenient at engine starting temperatures. Two important properties (although not the only properties required, as is known) of these additives are related to low temperature performance and cut stability. Performance at low temperatures is related to the preservation of a reduced viscosity at very low temperatures, while the stability to the cut is related to the resistance of the polymeric additives to decompose into smaller chains when subjected to mechanical stress in an engine. . In "Polymerization of ethylene and propylene to amorphous copolymers with catalysts of vanadium oxichloride and alkyl aluminum halides" (Polymerization of ethylene and propylene to amorphous copolymers with catalysts of vanadium oxychloride and aluminum alkyl halides), E. Junghanns, A. Gumboldt and G. Bier, Makromol. Chem. V. 58. (12/12/62): 18-42, it is disclosed the use of a tubular reactor to produce an ethylene-propylene copolymer, in which the composition varies along the length of the chain. More specifically, this reference discloses the production of amorphous ethylene-propylene copolymers, in a tubular reactor, with the use of Ziegler catalysts which are prepared based on a vanadium and aluminum alkyl compound. It is disclosed that ethylene polymerizes preferentially at the beginning of the tube and, when no additional replenishment of the monomer mixture is made during polymerization, the concentration of the monomers changes in favor of the propylene along the tube. It is further disclosed that, since these changes in concentrations occur during chain propagation, copolymer chains containing more ethylene are produced at one end than at the other end. It is also disclosed that the copolymers made in a tube are not chemically uniform, but fairly uniform with respect to molecular weight distribution. With the use of the data reported in Figure 17 for the copolymer prepared in the tube, it was estimated that the M Mn ratio for this copolymer was 1.6 and, based on its Figure 18, that the dispersion of intermolecular composition (Inter- CD, which is explained in detail below) of this copolymer was greater than 15%. J.F. Wehner, in "Laminar Flow Polymerization of EPDM Polymer" (Polymerization by Polymer Laminar Flow of EPDM) ACS Svmposium Series 65- pp. 140-152 (1978), discloses the results of a computer simulation work comprised to determine the effect of solution polymerization in a tubular reactor, with Ziegler catalysts, on the molecular weight distribution of the polymer product. The simulated specific polymer was an elastomeric terpolymer of ethylene-propylene-1,4-hexadiene. On page 149, it is expressed that, since the monomers have different reactivities, a polymer of variable composition is obtained when the monomers are exhausted. However, it is not distinguished if the composition varies intermolecularly or intramolecularly. In Table III on page 148, several polymers having an Mp / Mn <are predicted; * e approximately 1.3. In the third paragraph on page 144, it is stated that, as the diameter of the tube increases, the molecular weight of the polymer is too low to have a practical interest, and it is predicted that the reactor will be clogged. It is implied in the first paragraph of page 149 that the dispersion of composition produced in a tube would be harmful to the quality of the product. U.S. Patent No. 3,681,306, issued to Wehner, is directed to a process for producing higher ethylene / alpha-olefin copolymers having a good processability, by polymerization in at least two consecutive reactor stages. According to this reference, this two-stage process provides a simple polymerization process that allows copolymers of ethylene / alpha-olefins having predetermined properties, particularly those that contribute to the processing capacity in commercial applications, as a flow in cold, high raw strength and manufacturing capacity. According to this reference, the inventive process is particularly adapted to produce elastomeric copolymers, such as ethylene / propylene / 5-ethylidene-2-norbornene, with the use of any of the coordination catalysts useful for making EPDM. The preferred process employs a tubular reactor with a subsequent crucible reactor. However, it is also disclosed that a tubular reactor could be used, but operated under different reaction conditions to simulate two stages. As seen in column 2, lines 14-20, the process of the invention makes polymers of DPM broader than those made in a single-stage reactor. Although it is disclosed that the intermediate polymer from the first reactor (pipe) has an M / Mn ratio of about 2, as disclosed in column 5, lines 54-57, the final polymers, produced by the process of the invention have an M / Mn of 2.4 to 5. US Patent No. 3,625,658, issued to Closon, discloses a closed circuit, tubular reactor apparatus with high recirculation rates of the reactants, which can be used for make ethylene and propylene elastomers. With particular reference to Figure 1, a hinged support 10 for the vertical leg 1 of the reactor allows the horizontal expansion of its lower leg and avoids the damaging deformations due to thermal expansions, particularly those that are experienced during the cleaning of the reactor.
U.S. Patent No. 4,065,520 issued to Bailey et al. , discloses the use of a batch reactor to make ethylene copolymers, with the inclusion of elastomers, which have broad compositional distributions. Several feed tanks for the reactor are arranged in series, and the feed to each is varied to make the polymer. The products made have crystalline to semicrystalline to amorphous regions and gradient changes in medium. The catalyst system can employ vanadium compounds alone or in combination with a titanium compound and is exemplified by the vanadium oxy-tri-chloride and the diisobutyl-aluminum chloride. In all examples, titanium compounds are used. In several examples, hydrogen and diethyl zinc, known transfer agents, are used. The polymer chains produced have a first dispersed length in composition and a second uniform length. The later lengths have various other composition distributions. In "Estimation of Long-Chain Branching in Ethylene-Propylene Terpolymers from Infinite-Dilution Viscoelastic Properties" (Estimation of Long Chain Branching in Ethylene-Propylene Terpolymers with Base in Visible Properties of Infinite Diffusion), Y. Mitsuda, J. Schrag and J. Ferry; CT. Appl. Pol. Sci. 18, 193 (1974), copolymers of narrow DPM, with ethylene-propylene, are disclosed. For example, in Table II on page 198, EPDM copolymers having an M Mn of 1.19 to 1.32 are disclosed. In "The Effect of Molecular Weight and Molecular Weight Distribution on the Non-Newtonian Behavior of Ethylene-Porpilene-Diene Polymers (Effect of Molecular Weight and the Distribution of Molecular Weight on the Non-Newtonian Behavior of Ethylene-Propylene-Diene Polymers), Trans. Soc. Rheol .. 14-83 (1970), CK Shih, a complete series of homogeneous composition fractions was prepared and disclosed For example, the data in Table I disclose Polymer Sample B which Also, based on the reported data, the MPD of the sample is very narrow, however, it is not disclosed that the polymers have intramolecular dispersity. et al, is related to narrow molecular weight distribution copolymers, ethylene and at least one other alpha-olefin monomer, which copolymer is intramolecularly heterogeneous and intermolecularly homogeneous. It is disclosed that copolymers are useful in lubricating oils as viscosity index improvers. The MPE of the copolymers is characterized by at least one M Mn less than 2 and Mz / M less than 1.8. The copolymers are preferably made in a tubular reactor and the beneficiary of the patent discloses that various copolymer structures can be prepared by adding additional monomer (s) during the course of the polymerization. In Figure 4 (in which the% by weight of ethylene is plotted at a point on the chain's outline with respect to the fractional length along the chain's contour), a series of polymer contours is illustrated, with the use of multiple ethylene feeds along the tube in a tubular reactor. U.S. Patent No. 4,135,044, issued to Beals, relates to the production of polyethylene by polymerization of ethylene alone, or with comonomers and / or telogens in an elongated tubular reactor having an inlet and outlet and a plurality of reaction zones followed by cooling zones, in which a lateral stream of monomer is introduced at least after the first and second reaction zones. U.S. Patent No. 3,035,040, issued to Findlay, relates to a multistage 1-olefin polymerization process in which the catalyst, olefin and diluent are continuously introduced into a tubular reaction zone., extremely elongate, of small diameter, and the effluent from the same is passed to a stirred reactor (or a series of stirred reactors). The unreacted olefin and the diluent recovered from the polymerization of the second stage can be recirculated to the tubular zone, and the addition of multiple points of the recirculated diluent can be used for additional temperature control in the elongated reaction zone. The patent beneficiary employs aerodynamic or plug flow (ie, turbulent) conditions in the tubular reactor to improve the efficiency of the catalyst and prevent the removal of considerable quantities of unused catalyst from the effluent of this reactor, as in the case of turbulent flow conditions in the tubular reactor. US Patent No. 3,162,620, issued to Gladding, relates to copolymers and ethylene homopolymers which are prepared in the form of a coherent film on a liquid catalyst surface at rest. Representative publications dealing with ethylene-alpha-olefin copolymers as lubricating oil additives and other uses are as follows: US Patent No. 3,378,606, issued to Kontos, relates to semicrystalline / stereoblock copolymers (having a content of crystallinity from 4 to 40 percent) having rubber-plastic properties and comprising alternating blocks. The alternating blocks are recited combinations of crystalline, semicrystalline, crystallizable and amorphous homopolymers and copolymers. U.S. Patent No. 3,853,969, issued to Kontos, relates to hollow, stereoblock, crystallizable copolymers having at least three successive and alternating blocks of, eg, atactic, non-crystallizable, amorphous, ethylene-propylene copolymer, and crystallizable homopolymer of 1-olefin from C2 to C12.
U.S. Patent No. 3,380,978, issued to Ryan et al. , is related to a two-stage continuous coordination process, in series, in which the alpha-olefin is converted into a first stage (which can be achieved in a short, tubular retention reactor) in a high molecular weight fraction, which it has a broad molecular weight distribution, after which the polymer, the remaining catalyst and the unconverted monomer are passed directly to a second polymerization zone (an autoclave reactor, constant environment, longer retention), that a lower molecular weight fraction is formed, which has a narrower molecular weight distribution. U.S. Patent No. 3,389,087, issued to Kresge et al., Discloses lubricants containing ethylene-alpha-olefin polymers having a microstructure that is characterized by a high degree of alpha-olefin head-to-head bonds. Preferred copolymers show a degree of crystallinity of up to 25%. U.S. Patent No. 3,522,180 discloses ethylene and propylene copolymers having a number average molecular weight of 10,000 to 40,000 and a propylene content of 20 to 70 mole percent as I.V. in lubricating oils. The preferred M / Mn of these copolymers is less than about 4.0. U.S. Patent No. 3,551,336 issued to Jacobson et al., Discloses the use of ethylene copolymers of 60-80 per mole of ethylene, having no more than 1.3% by weight of a polymer fraction that is insoluble in decane normal to 55C as an oil additive. The reduction to a minimum of this insoluble decane fraction in the polymer reduces the tendency of the polymer to form turbidity in the oil, which turbidity is evidence of instability at low temperatures, probably caused by the adverse interaction with pour point reducing additives. . The M Mn of these copolymers is "surprisingly narrow" and is less than about 4.0, preferably less than 2.6, eg, 2.2. U.S. Patent No. 3,691,078, issued to Johnston et al., Discloses the use of ethylene-propylene copolymers containing 25-55% by weight of ethylene, which have an outstanding index of 18-33 and an average pending size. which does not exceed 10 carbon atoms as lubricating oil additives. The M / Mp is less than about 8. These additives impart good properties at low temperatures to the oil, with respect to the viscosity, without adversely affecting the pour point reducers. U.S. Patent No. 3,697,429, issued to Engel et al., Discloses a mixture of ethylene-propylene copolymers having different ethylene contents, ie, a first copolymer of 40-83% by weight of ethylene and an M / Mn less than about 4.0 (preferably, less than 2.6, for example, 2.2) and a second copolymer of 3-70% by weight of ethylene and an M Mn less than 4.0, and the content of the former differs from the latter by at least 4% by weight of ethylene. These mixtures, when used as I.V. in lubricating oils, they provide suitable viscosity properties at low temperatures, with minimal adverse interaction between the pour point reducer of the lubricating oil and the ethylene-propylene copolymer. U.S. Patent No. 3,798,288, issued to McManimie et al. , relates to a method for preparing ethylene-propylene copolymers (which are assumed to be "block" copolymers) comprising alternately polymerizing one of the monomers and mixtures of the monomers in the presence of a vanadium halide catalyst system. composed of aluminum alkyl. The polymer is characterized by alternating "blocks" of ethylene-propylene copolymer (the "heteropolymer") with "blocks" of ethylene (or propylene) homopolymer. A long chain of the homopolymer is followed by a long chain of the heteropolymer and this pattern can be repeated until the desired molecular weight of the copolymer is obtained. The polymerizations are carried out in a stirred reactor, equipped with two electrically driven turbines. US Patent No. 3,879,494, issued to Milkovitch et al., Relates to thermoplastic graft copolymer copolymers, separated in phase, chemically bound, which are prepared using macromonomers and which are characterized by a main structure and linear side chains. The linear side chains are prepared by living polymerization, with subsequent termination by reaction with a halogen-containing compound, which includes a polymerizable part. The finished living polymers, which have a narrow molecular weight distribution (MVMn <1: 1), are then copolymerized with a second monomer or second monomers during the formation of the main structure of the graft polymer. The side chains may comprise ethylene and lower alpha-olefins (although conjugated dienes of C4 to C12 and certain substituted vinyl aromatic hydrocarbons are preferred) and the second monomers may comprise alpha-olefins and comonomers comprising at least one vinylidene group and certain dienes conjugated and non-conjugated. US Patent No. 4,254,237, issued to Shiga et al., Is directed to propylene-ethylene copolymers (which are also assumed to be "block" polymers), which are prepared by a three step polymerization technique, in which the ethylene / propylene monomer ratios (and the percentages of the total polymerization amount) of the three steps are 6/94 or less (60-95% by weight), 15/85 to 79/21 (1-20% by weight) and 50/50 to 89/11 (4-35% by weight) in Steps 1, 2 and 3, respectively, and the ratio of the ethylene / propylene reaction in the third step is greater than in the second step . Polymerizations are achieved with the use of titanium trichloride and a catalyst system of organic aluminum compound. U.S. Patent No. 4,337,326, also issued to Shiga et al., Contains a similar disclosure and the ratios of the ethylene / propylene monomers of its three steps (and the percentages of the total polymerization amount) are 6/94 or less. (60-95% by weight), 25 / 74-67 / 33 (1-20% by weight) and 76/24 - 89/11 (4-35% by weight) in steps 1, 2 and 3, respectively , in which in steps 2 and 3 ethylene is supplied alone, thus gradually reducing the amount of propylene in the polymerization system from the first to the successive steps. U.S. Patent No. 4,414,369, issued to Kuroda et al. , is related to a continuous process for preparing polyolefins (based on C2 to C6 olefins) having widely distributed molecular weights, in a multistage polymerization, in which polymers of relatively high molecular weight are first formed, with subsequent formation of relatively low molecular weight polymers. U.S. Patent No. 4,480,075, issued to Willis, relates to block copolymers which are prepared by a Ziegler-Natta type polymerization, with subsequent conventional anionic polymerization. The patent beneficiary teaches that block copolymers with precise segmented structure, which can be obtained with long-life anionic systems, are not possible with the Ziegler-Natta catalysts because the olefin-type sequence copolymers get bogged down with large amounts of the corresponding homopolymers. The beneficiary of the patent indicates that this difficulty arises from the very short average life of the incipient chains in the Ziegler-Natta catalysis, mainly due to transfer reactions. U.S. Patent No. 4,499,242, issued to Loontjens, relates to propylene block copolymers, thermoplastics, comprising one or more essentially crystalline propylene blocks and one or more 1-alken propylene copolymer blocks. Diene units are present in at least one of the 1-alken propylene copolymer blocks. U.S. Patent No. 4,507,515, issued to Johnston et al., Relates to ethylene-alpha-olefin copolymers, useful for improving the viscosity properties at low temperature and pumping capacity of a lubricating oil comprising a major component and a minor, each of which has a defined ethylene sequence distribution with respect to the number of ethylenes in sequences of 3 or more and the percentage of ethylene sequences of 3 or more ethylene units. The major and minor components of the polymer are discrete polymers that can be prepared in separate reaction processes and mixed, or can be prepared on site in the same reaction process. U.S. Patent No. 4,575,574, issued to Kresge et al., (And its North American Division Patent, No. 4, 666, 619), is related to terpolymers or tetrapolymers of ethylene, useful as a viscosity modifier, and to a process for preparing the polymer. The patent discloses that a stirred tank, continuous flow reactor, or a tubular reactor can be employed. U.S. Patent No. 4,620,048, issued to Ver Strate et al., Discloses fluid solutions of polydispersed polymers having improved resistance to mechanical cutting. European Patent Application No. 60,609, Oda et al., Relates to ethylene / alpha-olefin copolymers containing from 30 to 90 mol% of ethylene and having a value of Q (M- / Mn) of no more than 3 and a Z value of 15 to 200. (The value of Z is defined as the ratio of the maximum value of the molecular weight to the minimum value of the molecular weight, which is measured by gel filtration chromatography). It is disclosed that the copolymer is useful as a fuel component or synthetic lubricating oil, having numerical average molecular weights of 300 to 30,000 and formed by continuous polymerization by feeding the catalyst components, olefin monomers, hydrogen and, optionally, , an intermediate element to the polymerization system. European Patent Application No. 59,034, by Horada et al., Is directed to a process for producing copolymers of ethylene with alpha-olefins (and ethylene / alpha-olefin / polyene terpolymers), in which two polymerization reactors are employed in series and operated at different temperature levels. It is disclosed that the polymers have an excellent processing capacity. Y. Doi et al., In "Block Copolymerization of Propylene and Ethylene with the" Living "Coordination Catalyst V (acac) 3 / Al (C2H5) 2 Cl / Anisole" (Copolymerization of Propylene and Ethylene Block with the Coordination Catalyst " Living "V (acac) 3 / Al (C2H5) 2Cl / Anisole" p.225-229, Makromol, Chem. Ranid Commun. Vol. 3 (1982), discloses the preparation of PR and PRP block copolymers, of syndiotactic propylene (P) blocks and random ethylene-propylene (R) copolymer blocks of narrow M / Mn ratios (1.22 to 1.24) G.C. Evens, in "Living Coordination Polymerization", 1981 Michigan Molecular Institute on Transition Metal Catalyzed Polimerizations: Unsolved Problems, pgs. 245-265 (1981), is also related to attempts to prepare copolymers of M Mj ratio. narrow (1.5-1.8) consisting of syndiotactic polypropylene blocks and an ethylene-propylene rubber block (PP-EPM-PP). When the living polymerization was started with small amounts of propylene (very short first "p" block), it was reported that the M7M_ of the resulting P-R-P block copolymer was broader (ie, 2.1, Table III). BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings describe, for purposes of illustration only, the processes embodied in the present invention, in which: Figure 1 is a schematic representation of a process for producing a polymer according to the present invention. Figure 2 schematically illustrates the manner in which the process illustrated in Figure 1 can be integrated into a lubricating oil additive process. Figure 3 is a graphic illustration of a technique for determining the intra-CD of a copolymer. Figure 4 is a graphic illustration of copolymer structures disclosed in U.S. Patent No. 4,540,753. Figures 5 and 6 are graphic illustrations of TE-SSI and CCS with respect to the ethylene content, as obtained in Example 6. Figures 7-17 are graphic illustrations of the chains' contours of the comparative copolymers 3-1 , 3-2, 3-3, 3-4, 3-5, 3-6 and 3-7 and the illustrative copolymers 4-1, 4-2. 5-1 and 6-1, respectively, which are obtained as described in the Examples. SUMMARY OF THE INVENTION The present invention is directed to novel segmented copolymers of ethylene and at least one other alpha-olefin monomer; each copolymer is intramolecularly heterogeneous and intermolecularly homogeneous and at least one segment of the copolymer, which constitutes at least 10% of the sopolymer chain, is a crystallizable segment. For the purposes of this application, the term "crystallizable segment" is defined as each segment of the copolymer chain having a numerical average molecular weight of at least 700, in which the ethylene content is at least 55% by weight. weight. The remaining segments of the copolymer chain are referred to herein as the "low crystallinity segments" and are characterized by an average ethylene content of no greater than about 53% by weight. In addition, the copolymer DPM is very narrow. It is well known that the width of the molecular weight distribution (MWD) can be characterized by the relationships of the various molecular weight averages. For example, an indication of a narrow MPE according to the present invention is that the ratio of the weight to the numerical average molecular weight (M / Mn) is less than 2. Alternatively, a ratio of the average molecular weight z to with respect to the weight average molecular weight (Mz / M) is less than 1.8 typifies at a narrow MPE according to the present invention. It is known that a portion of the proprietary advantages of the copolymers according to the present invention relate to these relationships. Fractions of reduced weight of material can disproportionately influence these relationships, although they do not significantly alter the property advantages that depend on them. For example, the presence of a reduced weight fraction (e.g., 2%) of low molecular weight copolymer can be reduced to Mn and thus raise to M / Mn above 2, while the M2 / Mn is maintained in less than 1.8. Therefore, the polymers, according to the present invention, are characterized by having at least one M / Mn less than 2 and one Mz / 1? less than 1.8. The copolymer comprises chains within which the ratio of the monomers varies along the length of the chain. To obtain the heterogeneity of intramolecular composition and narrow DPM, the copolymers according to the present invention are preferably made in a tubular reactor. It has been discovered that, in order to produce these copolymers, the use of numerous method steps not previously disclosed, performed within preferred ranges, not disclosed hitherto, is required. Accordingly, the present invention is also directed to a method for making the novel copolymers of the present invention. The copolymers according to the present invention have been shown to have improved properties in oleaginous fluids, in particular, in lubricating oil. The novel solvents of this invention are useful in lubricants, especially lubricants intended for use in the crankcase of internal combustion engines, gears and power transmission units. Accordingly, one or more objects of the invention are achieved by providing lubricating oil compositions, for example, fluids for automatic transmissions, heavy duty oils, suitable for use in crank shafts of gasoline and diesel engines, etc., which contain the novel copolymers of this invention. These lubricating oil compositions may contain additional additives, such as other viscosity modifiers, ashless dispersants, antioxidants, corrosion inhibitors, detergents, pour point depressants, anti-wear agents, etc. We have surprisingly found • the ethylene-alpha-olefin of this invention having distributions intramolecular composition and degree of specific crystallinity, provide lubricating oils having highly desirable viscosity properties and pumping capacity at low temperatures and good capacity of filtering at room temperature. Therefore, the present invention is also directed to a novel composition of additives for oils, comprising mineral oil of base material, lubricating viscosity, containing an effective amount of a viscosity modifier which is a copolymer according to the present invention. Detailed Description of the Invention Not wng to be bound by theory, it is believed that the improved function of novel copolymers as viscosity modifiers can be attributed, at least partially, to the capacity of a controlled portion of the copolymer molecules to "crystallize" in lubricating oils at temperatures above the dew point of the lubricating oil. By "crystallize" we mean that the methylene sequences in the polymer associate in some ordered state. The above happens both intermolecularly and intramolecularly. The base materials of lubricating oils usually contain paraffinic and isoparaffin wax components that are capable of crystallization. As a base material cools from elevated temperatures, a temperature is reached at which these wax components begin to crystallize. When the crystals become large, they scatter the light and make the oil cloudy. The above is called "dew point," whose temperature can be determined using the ASTM D-2500 test procedure. Below the point of condensation or darkness, the waxes of the base material can be co-crystallized with segments of crystallizable VM polymers, effectively interweaving the VM polymer molecules, which results in "effective" elevated polymer molecular weights, or they produce the "gelation" of the oil, which is observed by the appearance of a yielding effort when cutting. These high molecular weights are undesirable, since they increase the viscosity of the oil at low temperatures, making it difficult to pump or pour the oil. The associated polymer molecules of this invention are considered to have a lower hydrodynamic volume than in their unassociated state, which reduces the relative viscosity of their lubricating oil solution and provides low viscosities of the formulated oils at low temperatures. It is believed that the characteristics of the copolymer of exhibiting a polymer association temperature higher than the dark point of the oil, reduces to a minimum the interaction with the wax in the oil and, consequently, decreases the tendency of the oils to suffer gelatinization,. Also, only a portion of these newly discovered polymer molecules is crystallizable under the conditions of use. It is believed that the non-crystallizable portion acts as an estearic barrier to help prevent an excessive intermolecular association. The controlled segmented nature of polymers is essential for their performance. In addition, the location of the crystallizable segments is essential. Most preferably, the ethylene content of the crystallizable segments of the copolymers of this invention should not exceed about 75% by weight of ethylene to avoid increasing the temperature of association of the polymer to the point where a significant association of the polymer chains above ambient temperature, which would result in a poor filtering ability of the lubricating oils containing the copolymer. The temperature of association of the polymers (Ta) can be determined by studying the dependence of the temperature on the relative viscosity (? Reí). The deviation from an establd trend occurs when a significant association T is initiated (ASTM method D445 for kinematic viscosity can be applied to a series of temperatures.) The polymer concentration in these measurements should be the same as in the formulated oil, for example, about 1% by weight.) If the polymer has already been associated above the point of darkness temperature, the polymer and the wax have little opportunity to interact. In addition, when the polymer contains segments that are sufficiently low in ethylene to completely avoid crystallization and are suitably located along the contour, they will act as steric blocks for interaction with the wax or excessive polymer / polymer. In this way two characteristics of the polymers are needed: crystallization above the wax appearance temperature and a segmented structure to stabilize the agglomeration before the gels are formed. As noted above, the present invention is directed to novel segmented ethylene copolymers and at least one other alpha-olefin monomer, wherein the copolymer chain contains at least one crystallizable segment of ethylene monomer units, such as will be described more fully below, and at least one segment of low crystallinity ethylene-alpha-olefin copolymer, wherein the low crystallinity copolymer segment is characterized, in the unoriented bulk state, after or at least 24 hours of annealing, by a degree of crystallinity of less than 0.2% approximately, at 23 BC, and in which the copolymer chain is intramolecularly heterogeneous and intermolecularly homogeneous, and has a DPM that is characterized by at least one Mp / Mn less than 2 and one Mz / Mp less than 1.8. The crystallizable segments comprise approximately 10 to 90% by weight, preferably, approximately 20 to 85% by weight and, more preferably, at least approximately 60% by weight and, most preferably, at least around 63% by weight and not more than 95% by weight, preferably, <; 85% and, most preferred, < 75% by weight (for example, from approximately 58 to 68% by weight). The low crystallinity copolymer segments comprise about 90 to 10% by weight, preferably about 80 to 15% by weight and, more preferably, about 65 to 35% by weight of the total copolymer chain and contain a average ethylene content of about 20 to 53% by weight, preferably, about 30 to 50% by weight and, more preferably, about 35 to 50% by weight. The copolymers according to the present invention comprise intramolecularly heterogeneous chain segments, in which at least two portions of an individual intramolecularly heterogeneous chain, in which each portion comprises at least 5 percent by weight of the chain and which has a weight molecular weight of at least 7000, contain at least 5% by weight of ethylene and differ in composition from each other by at least 5% by weight of ethylene, wherein the dispersion of intermolecular composition of the polymer is such that 95% by weight of the polymer chains have a composition 15% or less different in ethylene with respect to the percentage by average weight of the ethylene composition, and in which the copolymer is characterized by at least one of a ratio of M PM less than 2 and a MzMp ratio less than 1.8. As described above, the copolymers of this invention will contain at least one crystallizable segment, rich in methylene units (hereinafter referred to as "M" segment) and at least one segment of ethylene-alpha-olefin copolymer, of low crystallinity (hereinafter referred to as "T" segment). Therefore, the copolymers can be illustrated by copolymers selected from the group consisting of copolymer chain structures having the following segment sequences: MT (I) T - (M-T2) x, and (II) T1- (M1 -T2) and-M2 (III) in which M and T are as defined above, M 1 and M 2 can be the same or different and are each segments M, T 1 and T 2 can be the same or different and are each segments T, x is an integer from 1 to 3 and y is an integer from 1 to 3. In structure II (x = l), the M segment of copolymer is located between two T segments, and the M segment can be located essentially in the center of the polymer chain (ie, the segments T1 and T2 may have essentially the same molecular weight and the sum of the molecular weight of the segments T1 and T2 may be essentially equal to the molecular weight of the M segment), although it is not essential for the practice of this invention. Preferably, the copolymer will contain only one M segment per chain. Therefore, structures I and II (x = l) are preferred. Preferably, the M segments and the T segments of the copolymer are located along the copolymer chain, so that only a limited number of the copolymer chains can be associated before the steric problems associated with the packing of the segments T of low crystallinity prevent further agglomeration. Therefore, in a preferred embodiment, the segment M is located near the center of the copolymer chain and only one segment M is in the chain. As will be shown below, the copolymers of the structure M1- (T-M2) z (IV) (in which M1, M2 and T are as defined above, and in which x is an integer of at least 1) are undesirable as viscosity modifying polymers. It has been found that the solutions of copolymers of structure IV in oil tend to gelatinize although the portions M and T have exactly the same composition and molecular weight as the copolymers of structure II (with x = z = l). It is believed that this poor performance as a viscosity modifier is due to the inability of a central T segment to stabilize sterically against association. The M segments of the copolymers of this invention comprise ethylene and may also comprise at least one other alpha-olefin, for example, containing from 3 to 18 carbon atoms. The segments T comprise ethylene and at least one other alpha-olefin, for example, alpha-olefins containing from 3 to 18 carbon atoms. The segments M and T may also comprise other polymerizable monomers, for example, non-conjugated dienes or cyclic monoolefins. As the present invention is considered to be most preferred in the context of ethylene-propylene copolymers, or ethylene-propylene-diene terpolymers (EPDM), it will be described in detail in the context of EPM and / or EPDM. The copolymer, according to the present invention, is preferably made in a tubular reactor. When it is produced in a tubular reactor with monomer that is fed only at the inlet of the tube, it is known that, in the principle of the tubular reactor, ethylene, due to its high reactivity, will polymerize preferentially. The concentration of monomers in solution changes along the tube in favor of propylene when the ethylene is exhausted. The result, with the monomer that is fed only at the inlet, are copolymer chains that have a higher ethylene concentration in the chain segments that grow near the reactor inlet (defined at the point at which the reaction begins. polymerization) and a higher concentration of propylene in the chain segments formed near the outlet of the reactor. These chains of copolymers, therefore, have a tapered composition. An exemplary ethylene-propylene copolymer chain is presented schematically below, in which E represents the constituents of ethylene and P the propylene constituents in the chain: 1 2 3 4 Segment: EEEEPEEEPPEEPPPEPPPP As can be seen based on this illustrative schematic chain , its extreme left-hand segment (1) represents that portion of the chain that forms at the reactor inlet, where the reaction mixture is proportionally richer in the more reactive ethylene constituent. This segment comprises four molecules of ethylene and one molecule of propylene. However, as later segments from left to right are formed and the more reactive ethylene is exhausted and the reaction mixture increases proportionally in propylene concentration, the subsequent chain segments become more concentrated in propylene. The resulting chain is intramolecularly heterogeneous. In the case where more than two monomers are used, for example, in the production of EDPM with the use of a diene thermonomer, for the purposes of describing the present invention all the properties related to homogeneity and heterogeneity will refer to the relative proportion of ethylene with respect to the other monomers in the chain, or any segment thereof. The property of the copolymer disclosed herein, in relation to the dispersion of intramolecular composition (variation of composition within a chain), will be called Intra-CD, and that related to the dispersion of intermolecular composition (variation of composition between chains ) will be called Inter-CD. In the case of the copolymers according to the present invention, the composition may vary between chains, as well as along the length of the chain. An object of this invention is to reduce the amount of variation between chains to a minimum. The inter-CD can be characterized by the difference in composition between the copolymer fractions that contain the highest amount of ethylene. The techniques for measuring the width of the Inter-CD are known according to the illustrations by Junghanns et al. (cited above), in which a p-xylene / dimethylformamide / non-solvent solvent was used to fractionate the copolymer in fractions of different intermolecular composition. Other solvent / non-solvent systems, such as hexane / 2-propanol, may be employed, as will be discussed in more detail below. The Inter-CD of the copolymer according to the present invention is such that 95% by weight of the copolymer chains have an ethylene composition that differs from the ethylene composition in percent by weight average by 15% by weight or weight. less. The preferred Inter-CD is about 13% or less and the most preferred is about 10% or less. Compared, Junghanns et al. they found that their tubular reactor copolymer had an Inter-CD greater than 15% by weight. Broadly, the Intra-CD of the copolymer according to the present invention is of such a nature that at least two portions of an individual intramolecularly heterogeneous chain, wherein each portion comprises at least 5 percent by weight of the chain, they differ in composition from one another by at least 7 percent by weight of ethylene. Unless otherwise indicated, this property of Intra-CD as referred to herein, is based on at least two 5 weight percent portions of the copolymer chain. The intra-CD of the copolymer according to the present invention may be such that at least two portions of the copolymer chain differ by at least 10 weight percent ethylene. It is also considered that differences of at least 20 percent, as well as at least 40 percent by weight of ethylene, are in accordance with the present invention. The experimental procedure to determine the Intra-CD is as follows. First, the Inter-CD is established as described below, then the polymer chain is divided into fragments along its contour and the Inter-CD of the fragments is determined. The difference in the two results is due to the Intra-CD, as can be seen in the illustrative example that follows. Consider a heterogeneous sample polymer, containing 30 monomer units. It consists of 3 molecules designated A, B, C. A EEEEPEEEPEEEPPEEPPEPPPEPPPPPPP B EEEEEPEEEPEEEPPEEEPPPEPPPEEPPP C EEPEEEPEEEPEEEPEEEPPEEPPPEEPPP Molecule A is 36.8% by weight of ethylene, B is 46.6% and C is 50% ethylene. The average ethylene content for the mixture is 44.3%. For this sample, the Inter-CD is of such a nature that the largest ethylene polymer contains 5.7% more ethylene than the average, while the polymer with the lowest ethylene content contains 7.5% less ethylene than the average. Or, in other words, 100% by weight of the polymer is within + 5.7% and -7.5% ethylene around an average of 44.3%. Accordingly, the Inter-CD is 7-5% when the given weight% of the polymer is 100%. The distribution can be represented schematically by, for example, curve 1 in Figure 2. When the chains are divided into fragments, there will be a new Inter-CD. For simplicity, we will first consider dividing only molecule A into fragments, which are shown by the cuts as follows: EEEEP / EEEPE / EEPPE / EPPEP / PPEPP / PPPPP Portions of 72.7%, 72.7%, 50%, 30.8%, 14.3 are obtained % and 0% ethylene. When molecules B and C are divided in a similar manner and the weight fractions of similar composition are grouped, the new Inter-CD is obtained, which is shown by curve 2 in Fig. 3. The difference between the two curves in the figure it is due to the Intra-CD. The consideration of these data, especially near the amplitudes of end points, shows that, for this sample, at least 5% of the chain contour represented by the amplitude of% by cumulative weight (a) differs in composition from another section in at least 15% ethylene shown as (b), the difference between the two curves. The difference in composition represented by (b) can not be intermolecular. If it were, the separation process for the original polymer would have revealed the highest ethylene content observed only for the degraded chain. The composition differences shown by (b) and (d) in the figure, between original and fragmented chains, provide minimum values for the Intra-CD. The Intra-CD must be at least as large, because chain sections have been isolated which are the difference given in composition (b) or (d) with respect to the polymer of higher or lower composition, isolated from the original. We know in this example that the original polymer represented in (b) had sections of 72.7% ethylene and 0% ethylene in the same chain. It is highly probable that, due to the inefficiency of the fractionation process, any real polymer with Intra-CD examined will have sections of higher or lower ethylene connected along its contour than what is shown by the extreme points of the fractionation. In this way, this procedure determines a limit for Intra-CD. To improve detection, the original whole polymer can be fractionated (for example, separating molecule A from molecule B from molecule C in the hypothetical example), with these fractions being fractionated again until they show no (or less) Inter- CD. The subsequent fragmentation of this intermolecularly homogeneous fraction now reveals the total intra-CD. In principle, for the example, if the molecule A were isolated, fragmented, fractioned and analyzed, the Intra-CD for the chain sections would be 72.7-0% = 72.7%, instead of 72.7-50% = 22.7 % that is seen when fractionating the entire mixture of molecules A, B and C. In order to determine the fraction of a polymer that is intramolecularly heterogeneous in a mixture of polymers combined from several sources, the mixture must be separated into fractions that do not show no further heterogeneity when fractioned subsequently. These fractions are subsequently fractured and fractionated to reveal which are heterogeneous. The fragments into which the original polymer is divided should be large enough to avoid extreme effects and give a reasonable opportunity for the normal statistical distribution of segments to be formed at a given conversion amplitude of monomers in the polymerization. Intervals of about 5% by weight of the polymer are convenient. For example, with an average polymer molecular weight of about 105, fragments of about 5000 molecular weight are suitable. A detailed mathematical analysis of the batch polymerization or plug flow indicates that the rate of change of the composition along the polymer chain contour will be more severe in the conversion of high ethylene, near the end of the polymerization. The shortest fragments are needed here to show the sections of low ethylene content. The best available technique for the determination of composition dispersity for non-polar polymers is solvent / non-solvent fractionation based on the thermodynamics of phase separation. This technique is described in "Polymer Fractionation", M. Cantow, editor, Academic 1967, p. 341 ff and in M. Inagaki, T. Tanaku, "Developments in Polymer Characterization", 3, 1, (1982). The foregoing are incorporated herein by reference. For the non-crystalline copolymers of ethylene and propylene, the molecular weight governs the insolubility more than the composition in a solvent / non-solvent solution. The high molecular weight polymer is less soluble in a given solvent mixture. There is also a systematic correlation of the molecular weight with the ethylene content for the polymers described herein. Since ethylene polymerizes much faster than propylene, the polymer with high ethylene content also tends to be of high molecular weight. Additionally, ethylene-rich chains tend to be less soluble in hydrocarbon / polar non-solvent mixtures than are the propylene-rich chains. In addition, for the crystalline segments, the solubility is reduced significantly. In this way, chains of high ethylene content, of high molecular weight, are easily separated on the basis of thermodynamics. A fractionation process is as follows: the unfragmented polymer is dissolved in n-hexane at 23 ° C to form approximately 1% solution (1 g of polymer / 100 cc of hexane). Isopropyl alcohol is titrated in the solution until turbidity appears, at which time the precipitate is allowed to settle. The floating liquid is removed and the precipitate is removed by pressing between a film of Mylar® (polyethylene terephthalate) at 150 ° C. The ethylene content is determined by the ASTM D-3900 method. The titration is resumed and the subsequent fractions are re-examined and analyzed until 100% of the polymer is collected. The titrations are ideally controlled to produce fractions of 5-10% by weight of the original polymer, especially at the ends of the composition.
To demonstrate the width of the distribution, the data are plotted as% ethylene with respect to the cumulative weight of the polymer, defined by the sum of half of the% by weight of the fraction of that composition, plus the% by total weight of the composition. the fractions collected previously. Another portion of the original polymer is divided into fragments. A suitable method for doing this is by thermal degradation according to the following procedure: in a sealed vessel, in a furnace purged with nitrogen, a 2 mm thick layer of the polymer is heated for 60 minutes at 330 ° C. (Time or temperature can be adjusted empirically based on the ethylene content and the molecular weight of the polymer). The foregoing should be suitable for reducing a molecular weight polymer of 105 to fragments of about 5000 molecular weight. This degradation does not considerably change the average ethylene content of the polymer, although propylene tends to be lost in cleavage in preference to ethylene. This polymer is fractionated by the same procedure as the high molecular weight precursor. The ethylene content is measured, as well as the molecular weight, in selected fractions. The procedure for characterizing intramolecular heterogeneity is laborious and, although it is performed in an absolute optimal manner, it does not show how the segments of the chain are connected. In reality, it is not possible, with current technology, to determine the structure of the polymer without resorting to the conditions of synthesis. With knowledge of the synthesis conditions, the structure can be defined as follows: Polymerizations of ethylene, propylene or higher alpha-olefin, with transition metal catalysts, can be described by the terminal copolymerization model, to a suitable approximation for the purpose I presented. (See Strate, Encvclopedia of Polymer Science and Engineering, vol.6, 522 (1986) In this model the relative reactivity of the two monomers is specified by two reactivity ratios, which are defined as follows: R1 = (constant of regime for ethylene added to ethylene) (steady state for propylene added to ethylene) R2 = (steady state for propylene added to propylene) (steady state for ethylene added to propylene) Given these two constants, at a given temperature, the ratio of the molar amount of ethylene, E, to the molar amount of propylene, P, which enters the chain from a solution containing ethylene and propylene in molar concentrations [E] and [P], is respectively: 1 = _ £ E1 • JR. TE] ± CPU (1) P [P] ([E] + R2 [P]) The ratio of E and P to the% by weight of ethylene in the polymer is as follows: E% by weight of ethylene = • 100 E + 1.5 P The values of R1 and R2 depend on the particular comonomer and catalyst used to prepare the polymer, the polymerization temperature and, to some degree, the solvent. For all transition metal catalysts specified herein, R1 is significantly greater than R2. In this way, as can be seen in equation (1), ethylene will be consumed faster than propylene for a given fraction of the monomer in the reaction medium. In this way, the ratio of [E] / [P] will decrease as the monomers are consumed. Only when! = 2 will the composition in the polymer be equal to that in the reaction medium. If the amount of monomer that has reacted at a given time in a batch reactor can be determined, or at a given point in a tubular reactor, it is possible, through equation (1) to determine the instantaneous composition that is being formed in a given point along the polymer chain. The demonstration of the narrow MPD and the increase of the Molecular Weight along the tube, proves that the distribution of composition is intramolecular. The amount of polymer that is formed can be determined in any of two ways. Sas of the polymerizing solution can be collected, with appropriate rapid cooling to terminate the reaction, at various points along the reactor, and evaluate the amount of polymer that is formed. Alternatively, when the polymerization is carried out in an adiabatic manner and the heat of the polymerization is known, the amount of converted monomer can be calculated based on the temperature profile of the reactor. Finally, when the average composition of the polymer is measured in a series of locations along the tube, or at various times in the case of batch polymerization, it is possible to calculate the instantaneous composition of the polymer being made. This technique does not require knowing R1 and R2 or the heat of the polymerization, but does require access to the polymer synthesis step. All these methods have been used with uniform results. For the purposes of this patent, R1 and R2 thus simply serve to characterize the composition of the polymer in terms of the polymerization conditions. By defining R1 and R2 we can specify the distribution of intramolecular composition. In the examples shown below, in which VC14 and ethylaluminum sesquichloride in hexane are used as solvent, R., = 1.8 exp (+ 500 / RTk) and R2 = 3.2 exp (-1500 / RTk). In which "R" is the gas constant (1.98 cal / deg-mol) and "T" are Kelvin degrees. For reference, at 20. C R1 = 9.7, R2 = 0.02. In Figures 4 and 7-17, the intramolecular composition distributions have been calculated with the use of these R., R2, the known reactor feed conditions, the polymerization heat observed in the adiabatic reactor and the following expressions that relate the heat of the polymerization and the composition of the polymer.
Polymerization heat = 485 + 317 x (E / (E + P)) cal / g (2). The R., and R2 provided above predict the correct final average polymer composition. When it is found that R1 and R2 and expression (2) are inaccurate, someday the distribution of intramolecular polymer composition will continue as defined herein in terms of the polymerization conditions, but may have to be modified based on the composition scale absolute that is presented in Figures 7-17. There is little chance that they are wrong in more than a small percentage, however. The ethylene content is measured by the method ASTM D3900 for the ethylene-propylene copolymers, between 35 and 85% by weight of ethylene. Above 85%, ASTM-D2238 can be used to obtain compositions of the methyl group which are related to the percentage of ethylene in an unambiguous manner for the ethylene-propylene copolymers. When non-propylene comonomers are used, there is no ASTM test covering a wide range of ethylene content; however, carbon-13 nuclear magnetic resonance spectroscopy and protons can be used to determine the composition of said polymers. The previous ones are absolute techniques that do not require any calibration when they are operated in such a way that all the cores of a given element contribute to the spectra. For the amplitudes not covered by the ASTM tests for the ethylene-propylene copolymers, these methods of nuclear magnetic resonance can also be employed. Molecular weight and molecular weight distribution are measured with the use of a gel filtration chromatograph, Waters 150C, equipped with Chromatix KMX-6 line light diffusion photometer (LDC-Milton Roy, Riviera Beach, Fia.) The system is used at 135 BC with 1, 2, 3, 4-trichlorobenzene as the mobile phase. Showdex polystyrene gel columns (Showa-Denko America, Inc.) 602, 803, 804 and 805 are used. This technique is discussed in "Liquid Chromatography of Polymers and Related Materials III" (Liquid Polymer Chromatography and Related Materials III) , J. Cazes editor, Marcel Dekker, 1981, p. 207 (which is incorporated herein by reference). No corrections are used to spread columns; however, data on generally accepted standards, for example, the National Bureau of Polyethylene Standards 1484 and the hydrogenated polyisoprene produced anionically (an alternating ethylene-propylene copolymer) show that such corrections on M / Mn or Mz / M They are less than 0.05 units. MJM. it is calculated based on an elution-molecular weight ratio, while Mz / M is evaluated with the use of the light scattering photometer. The numerical analyzes can be executed with the use of the commercially available computer software, GPC2, M0LW 2, which can be obtained from the LDC / Milton Roy-Riviera Beach, Florida.
As already noted, the copolymers according to the present invention comprise ethylene and at least one other alpha-olefin. It is believed that this alpha-olefin could include those containing from 3 to 18 carbon atoms, for example, propylene, butene-1, pentene-1, etc. Alpha-olefins of 3 to 6 carbons are preferred due to economic considerations. The most preferred copolymers according to the present invention are those comprising ethylene and propylene, or ethylene, propylene and diene. As is well known to those skilled in the art, copolymers of ethylene and higher alpha-olefins, such as propylene, often include other polymerizable monomers. Typical of these other monomers may be the non-conjugated dienes, as the following non-limiting examples: a. straight chain acyclic dienes, such as: 1,4-hexadiene; 1, 6-octadiene; b. acyclic, branched chain dienes, such as: 5-methyl-1,4-hexadiene; 3, 7-dimethyl-l, 6-octadiene; 3,7-dimethyl-1, 7-octadiene and the mixed isomers of dihydro-myrcene and dihydrooclinene; c. single ring alicyclic dienes, such as: 1,4-cyclohexadiene; 1,5-cyclooctadiene; and 1, 5-cyclododecadiene. d. melt-ring and bridged dienes, alicyclic, of multiple rings, such as: tetrahydroindene; methyltetrahydroindene; dicyclopentadiene; bicyclo- (2, 2, 1) -hepta-2, 5-diene; alkenyl, alkylidene, cycloalkenyl and cycloalkylidene norbornenes, such as 5-methylene-2-norbornene (MNB); 5-ethylidene-2-norbornene (ENB), 5-propylene-2-norbornene, 5-isopropylidene-2-norbornene, 5- (4-iclopentenyl) -2-norbornene; 5-cyclohexylidene-2-norbornene. Of the non-conjugated dienes which are normally used to prepare these copolymers, dienes containing at least one of the double bonds in a ring under tension are preferred. The most preferred diene is 5-ethylidene-2-norbornene (ENB). The amount of diene (base per weight) in the copolymer could be from about 0% to 20%, with from 0% to 15% being preferred. The most preferred amplitude is from 0% to 10%. As already noted, the most preferred copolymer according to the present invention is ethylene-propylene or ethylene-propylene-diene. In any case, the average ethylene content in the copolymer could be as low as up to about 20% on a per-weight basis. The preferred minimum is approximately 25%. A minimum that is most preferred is approximately 30%. The maximum ethylene content could be about 90% on a per-weight basis. The preferred maximum is about 85%, and the most preferred is about 80%. Preferably, the copolymers of this invention, intended for use as viscosity modifiers, contain about 35 to 75% by weight of ethylene, and more preferably, about 50 to 70% of ethylene. The molecular weight of the copolymer made in accordance with the present invention can vary over a wide range. It is believed that the weight average molecular weight could be as low as about 2000. The preferred minimum is about 10,000. The minimum that is most preferred is approximately 20,000. It is believed that the maximum weight average molecular weight could be as high as up to about 12,000. The preferred maximum is approximately 1,000,000. The maximum that is most preferred is approximately 750,000. A weight average molecular weight range that is especially preferred for copolymers intended for use as polymers M.V. It is 50,000 to 500,000. The copolymers of this invention will also be characterized by a Mooney viscosity (ie, ML (1, + 4I) 125 ° C) of about 1 to 100, preferably about 10 to 70, and most preferably about from 15 to 65, and by a thickening efficiency ("EE") of about 0.4 to 5.0, preferably, about 1.0 to 4.0, most preferably, about 1.4 to 3.8. Another feature of the copolymer made in accordance with the present invention is that the molecular weight distribution (DPM) is very narrow, as characterized by at least one of a MJMn ratio of less than 2 and a lower Mz / M ratio of 1.8. Regarding EPM and EPDM, a typical advantage of those copolymers that have a narrow DPM of the resistance to degradation by cutting. Particularly for lubricating oil applications, the preferred copolymers have an M / Mn of less than about 1.5; the most preferred is less than about 1.25. The preferred Mz / M is less than about 1.5 and the most preferred is less than about 1.2. The processes according to the present invention produce copolymer by polymerization of a reaction mixture comprising a catalyst, ethylene and at least one additional alpha-olefin monomer, in which the amounts of monomer, and preferably ethylene, are varied during the course of the polymerization in a controlled manner as will be described below. Polymerizations by solution are preferred. Any known solvent can be used for the reaction mixture, which is effective for use, to carry out solution polymerizations according to the present invention. For example, suitable solvents would be hydrocarbon solvents, such as aliphatic, cycloaliphatic and aromatic hydrocarbon solvents, or halogenated versions of said solvents. Preferred solvents are saturated hydrocarbons, straight chain or branched chain, C12 or less; alicyclic or aromatic hydrocarbons, saturated, from C5 to C9; or halogenated hydrocarbons from C2 to C6. The most preferred are straight chain or branched chain hydrocarbons, of C12 or less, particularly hexane. Illustrative non-limiting examples of the solvents are butane, pentane, hexane, heptane, cyclopentane, cyclohexane, cycloheptane, methyl-cyclopentane, methyl-cyclohexane, isooctane, benzene, toluene, xylene, chloroform, chlorobenzenes, tetrachlorethylene, dichloroethane, and trichloroethane . These processes are carried out in a reactor system without mixing, which is one in which essentially no mixing occurs between portions of the reaction mixture containing polymer chains initiated at different times. Suitable reactors are a continuous flow tubular reactor, or a stirred batch reactor. A tubular reactor is well known and is designed to reduce to a minimum the mixing of the reactants in the direction of flow. As a result, the concentration of reactants will vary along the length of the reactor. In contrast, the reaction mixture in a stirred, continuous flow tank reactor (CFSTR) is combined with the inlet feed to produce a solution of essentially uniform composition at all reactor sites. Accordingly, the growing chains in a portion of the reaction mixture will have a variety of ages and, thus, a single CFSTR is not suitable for the process of this invention. However, it is well known that 3 or more tanks agitated in series with the entire catalyst that is fed to the first reactor, can approximate the performance of a tubular reactor. Accordingly, it is considered that these series tanks are in accordance with the present invention. A batch reactor is a suitable vessel, preferably equipped with suitable agitation, which is added to the catalyst, the solvent and the monomer at the beginning of the polymerization. The reagent loading is then allowed to polymerize for a sufficiently long time to produce the desired product, or chain segment. For economic reasons, a tubular reactor is preferred than a batch reactor for carrying out the processes of this invention. In addition to the importance of the reactor system for making copolymers according to the present invention, the polymerization must be carried out in such a way that: (a) the catalyst system produces essentially an active catalyst species, (b) the reaction mixture is essentially free of chain transfer agents, and (c) the polymer chains are all initiated essentially simultaneously, which is at the same time for a batch reactor, or at the same point along the length of the tube in the case of a tubular reactor. To prepare the structures of copolymers II and III above (and, optionally, to prepare the structure of copolymer I above), additional solvent and reagents (eg, at least one of ethylene, alpha-olefin and diene) will be added either along the length of a tubular reactor or during the course of polymerization in a batch reactor, or to selected steps of reactors stirred in series, in a controlled manner (as will be described below) to form the copolymers of this invention . However, it is necessary to add essentially all of the catalyst at the inlet of the tube or at the beginning of the batch reactor operation to satisfy the requirement that essentially all the polymer chains start simultaneously. Accordingly, the processes according to the present invention are carried out: (a) in at least one reactor without mixing, (b) with the use of a catalyst system that essentially produces a kind of active catalyst, (c) with the use of at least one reaction mixture that is essentially free of transfer agents, and (d) in such a way that, under sufficient conditions, the propagation of essentially all of the polymer chains begins simultaneously. Since the tubular reactor is the preferred reactor system for carrying out the processes according to the present invention, the following examples and illustrative descriptions are directed to that system, but will be applied to other reactor systems that readily occur to the artifices that have the benefit of this description. When practicing the processes according to the present invention, use is made of a tubular reactor, preferably. In this way, in its simplest form, a process of this nature would make use of a single reactor. However, as could easily occur to the architect who has the benefit of this disclosure, a series of reactors could be employed. multiple feed of monomers to vary the intramolecular composition, as described below. The structures described in US Patent No. 4,540,753 obtained by the addition of additional monomer (s) during the course of the polymerization are shown in curves 1-4 of Figure 4, in which the composition with respect to the position along the length of the chain's contour. The Intra-CD of curve 1 is obtained by feeding all the monomers at the entrance of the tubular reactor, or at the start of a batch reaction. In comparison, the Intra-CD of curve 2 is made by adding additional ethylene (and, optionally, propylene) at a point along the tube or, in a batch reactor, where the chains have reached approximately half of their length. The Intra-CD of Curve 3 requires multiple feed additions. The Intra-CD of curve 4 is formed when additional comonomer is added, instead of ethylene, thus allowing an amplitude of the complete ethylene composition of the chain to be omitted. The composition of the catalyst used to produce alpha-olefin copolymers has a profound effect on the properties of the copolymer product, such as the composition dispersity and the DPM. The catalyst used in carrying out the processes according to the present invention must be of such a nature that it essentially produces a kind of active catalyst in the reaction mixture. More specifically, it must produce a kind of primary active catalyst that provides essentially all of the polymerization reaction. The additional active catalyst species could provide up to 35% (weight) of the total copolymer. Preferably, they should represent approximately 10% or less of the copolymer. In this way, the essentially active species must provide at least 65% of the total copolymer employed, preferably at least 90% thereof. The degree to which a catalyst species contributes to the polymerization can be determined without problem with the use of the techniques described below to characterize the catalyst, according to the number of species of active catalysts. The techniques for characterizing the catalyst according to the number of species of active catalysts are within the capacity of the technique, as evidenced in the article entitled "Ethylene-Propylene Copolymers, Reactivity Ratios, Evaluation and Significance" (Ethylene Copolymers) -Propylene, Reactivity Relationships, Evaluation and Importance), C. Cozewith and G. Ver Strate, Macromolecules, 4, 482 (1971), which is incorporated herein by reference. The authors disclose that copolymers made in a stirred, continuous flow reactor should have a DPM characterized by M / Mn = 2 and a narrow Inter-CD when a species of active catalyst is present. By means of a combination of fractionation and gel filtration chromatography (GPC), it is shown that, for catalysts of single active species, the compositions of the fractions do not vary more than + 3% above the average and the DPM (weight average ratio with with respect to the numerical average), for these samples, it approaches 2. The latter characteristic (MJM of approximately 2) is considered the most important to identify a single species of active catalyst. On the other hand other catalysts provided the copolymer with an Inter-CD greater than + 10% above the average and multimodal DPM with an M Mn often greater than 10. These other catalysts are considered to have more than one active species. Catalyst systems for use in the execution of processes according to the present invention may be Ziegler catalysts, which may typically include: (a) a transition metal compound, i.e., a metal of Groups IB, III -B, IVB, VB. VIB, VIIB and VIII of the Periodic Table; and (b) an organic metal compound of a metal of Groups I-A, II-A, II-B and III-A of the Periodic Table. The preferred catalyst system for carrying out the processes according to the present invention comprises a hydrocarbon-soluble vanadium compound, in which the valence of vanadium is from 3 to 5, and an organic aluminum compound, with the proviso that the The catalyst essentially produces a kind of active catalyst as described above. At least one of the selected vanadium / aluminum organic compound pair must also contain a halogen linked by valence. In terms of formulas, the vanadium compounds useful for putting into practice the processes according to the present invention, could be: 0 II VCl? (OR) 3.? where x = 0-3 and R = a hydrocarbon radical; VC14; VO (AcAc) 2, in which AcAc = acetyl acetonate which may or may not be substituted alkyl (for example, C, to C6 alkyl); V (AcAc) 3; V (part dicarbonyl) 3; VOCl? (AcAc) 3.?, In which x = 1 or 2; V (part dicarbonyl) 3 Cl; and VCl3.nB, in which n = 2-3, B = Lewis base capable of making hydrocarbon-soluble complexes with VC13, such as tetrahydrofuran, 2-methyl-tetrahydrofuran and dimethyl-1-pyridine, and the dicarbonyl part is derived from a compound of dicarbonyl of the formula: RC-R'-CR II II oo In the formula (1) above, each R (which may be the same or different) represents, preferably, an aliphatic, alicyclic or aromatic hydrocarbon radical of C, a C10, such as ethyl (Et), phenyl, isopropyl, butyl, propyl, n-butyl, i-butyl, t-butyl, hexyl, cyclohexyl, octyl, naphthyl, etc. R preferably represents a divalent radical of alkylene of 1 to 6 carbon atoms (for example, -CH2-, C2H4-, etc.). Illustrative, non-limiting examples of the compounds of the formula (1) are vanadyl trihalides, alkoxy halides and alkoxides, such as VOCl 3, VOCl 2 (O Bu), in which Bu = butyl, and VO (OC 2 H 5) 3. The most preferred vanadium compounds are VC14, VOCl3 and V0C12 (OR). As already noted above, the joint catalyst is preferably an organic aluminum compound. In terms of chemical formulas, these compounds could be like A1R3, A1 (0R) R2, A1R2C1, R2A1 - A1R2, AIR 'RCl A1R2I, A12R3C13, and A1RC12, in which R and R 'represent hydrocarbon radicals, same or different, as described above with respect to the formula of the vanadium compounds. The most preferred organic aluminum compound is an aluminum alkyl sesquichloride such as Al2Et3Cl3 or A12 (ÍBU) 3C13. In terms of performance, a catalyst system comprising VC14 and A12R3C13, preferably wherein R is ethyl, has proven to be particularly effective. For better performance of the catalyst, the molar amounts of catalyst components that are added to the reaction mixture should provide an aluminum / vanadium (Al / V) molar ratio of at least about 2. The preferred minimum Al / V is 4 approximately. The maximum Al / V is based primarily on the considerations of the catalyst expense and the desire to reduce to a minimum the amount of chain transfer that can be caused by the organic aluminum compound (as explained in detail below). Since, as is known, certain organic aluminum compounds act as chain transfer agents, when there is too much present in the reaction mixture, the M_ / Mn of the copolymer may rise above 2. Based on these considerations, the Al / Maximum V could be about 25; however, a maximum of about 17 is preferred. The maximum ratio that is most preferred is approximately 15. With reference again to the processes for making a copolymer according to the present invention, it is well known that certain combinations of vanadium and aluminum compounds which may include the catalyst system, may cause branching and gelation during polymerization in the case of polymers. which contain high levels of diene. To prevent the above from occurring, Lewis bases, such as ammonia, tetrahydrofuran, pyridine, tributylamine, tetrahydrothiophene, etc., may be added to the polymerization system with the use of techniques well known to those skilled in the art. Chain transfer agents for the polymerization of alpha-olefins, catalysed with Ziegler catalysts, are well known and are illustrated, by way of example, by hydrogen or diethyl zinc for the production of EPM and EPDM. These agents are used in a very common way to control the molecular weight of EPM and EPDM that are produced in continuous flow stirred reactors. For Ziegler catalyst systems of essentially a single active species, which are employed in accordance with the present invention, the addition of chain transfer agents to CFSTR reduces the molecular weight of the polymer, but does not affect the molecular weight distribution. On the other hand, the chain transfer reactions during the polymerization in the tubular reactor, according to the present invention, extend the molecular weight distribution and the Inter-CD. In this way, the presence of chain transfer agents in the reaction mixture must be reduced to a minimum or completely omitted. Although it is difficult to generalize for all possible reactions, the amount of chain transfer agent that is employed should be limited to those amounts that provide copolymer product according to the desired limits with respect to the MWD and composition dispersity. It is believed that the maximum amount of chain transfer agent present in the reaction mixture could be as high as up to about 0.2 moles / mole of transition metal, for example, vanadium, on condition, again, that the product The resulting copolymer is in accordance with the desired limits in terms of DPM and composition dispersity. Even in the absence of added chain transfer agent, chain transfer reactions can occur because the propylene and the joint organic aluminum catalyst can also act as chain transfer agents. In general, among the organic aluminum compounds that produce only one active species in combination with the vanadium compound, the organic aluminum compound that provides the highest molecular weight of copolymer with an acceptable catalyst activity must be chosen. On the other hand, if the Al / V ratio has an effect on the molecular weight of the copolymer product, that Al / V which provides the highest molecular weight must be used, also with an acceptable catalyst activity. The chain transfer with propylene can be better limited by avoiding an excessively high temperature during the polymerization, as described below. The molecular weight distribution and the Inter-CD are also extended by catalytic deactivation during the course of the polymerization, which leads to the termination of the growing chains. It is well known that vanadium-based Ziegler catalysts, used in accordance with the present invention, are subject to deactivation reactions of such a nature that they depend, to a certain extent, on the composition of the catalyst. Although the ratio between the life of the active catalyst and the composition of the catalyst system is not known in the present, for any given catalyst, the deactivation can be reduced with the use of the shorter residence time and the lower temperature in the reactor that produce the conversions of desired monomers. The polymerizations, according to the present invention, must be carried out in such a manner and under conditions sufficient to initiate the propagation of essentially all of the copolymer chains simultaneously. The above can be achieved by using the steps and conditions of the process described below. The catalyst components are preferably mixed in advance, ie they are reacted to form the active catalyst outside the reactor, to ensure rapid initiation of the chain. The aging of the premixed catalyst system, ie the time spent by the catalyst components (for example, vanadium compound and organic aluminum) in the presence of one another outside the reactor, should preferably be kept within limits. If they are not aged for a sufficient period of time, the components will not have reacted with each other sufficiently to produce an adequate amount of active catalyst species and the result is the initiation of chains in a non-simultaneous manner. It is also known that the activity of the catalytic species decreases with time, so the aging must be kept below a maximum limit. It is believed that the minimum aging period, depending on factors such as the concentration of the catalyst components, the temperature and the mixing equipment, could be as low as up to approximately 0.1 seconds. The preferred minimum aging period is approximately 0.5 seconds, while the minimum preferred period of aging is approximately 1 second. Although the maximum aging period could be longer, for the vanadium / organic aluminum catalyst system, the preferred maximum is approximately 200 seconds. A maximum that is most preferred is approximately 100 seconds. The most preferred maximum aging period is approximately 50 seconds. Premixing could be carried out at a low temperature, such as 40 aC or lower. It is preferred that the premix is carried out at 25 ° C and most preferred is 20 ° C or less. Preferably, the catalyst components are pre-mixed in the presence of the selected polymerization diluent or solvent, under conditions of rapid mixing, for example, with Reynolds Shock Numbers (NRE) of at least 10,000 more preferably, at least 50,000 and, most preferably, at least 100,000. The Reynolds number of shock is defined as N, RE = DN μ in which N is the fluid flow velocity (cm / sec), D is the internal diameter of the tube (cm), and yy is the density of the fluid (gm) / cm3) and μ is the viscosity of the fluid (poise). The temperature of the reaction mixture must also be kept within certain limits. The temperature at the reactor inlets must be high enough to provide a rapid and complete chain initiation upon initiation of the polymerization reaction. The length of time that the reaction mixture passes at elevated temperatures must be sufficiently short to minimize the amount of undesirable chain transfer reactions and deactivation of the catalyst. Controlling the temperature of the reaction mixture is somewhat complicated by the fact that the polymerization reaction generates large amounts of heat. This problem is preferably handled with the use of a pre-cooled feed to be supplied to the reactor in order to absorb the polymerization heat. With this technique, the reactor operates in an adiabatic manner, and the temperature is allowed to increase during the course of the polymerization. As an alternative for pre-cooling the feed, heat can be removed from the reaction mixture, for example, by a heat exchanger surrounding at least a portion of the reactor, or by well-known self-cooling techniques, in the case of batch reactors or multiple reactors, agitated, in series. When the adiabatic reactor operation is employed, the inlet temperature of the reactor feed could be about -50aC to 1502C. It is believed that the exit temperature of the reaction mixture could be as high as about 200 BC. The preferred maximum outlet temperature is about 70 aC. The most preferred maximum is about 60 BC. In the absence of cooling of the reactor, for example, by means of a reactor jacket, to remove the heat of the polymerization, it has been determined (for an EP copolymer with ethylene content of the middle part of the amplitude and a solvent with capacity). thermal similar to hexane) that the temperature of the reaction mixture will increase from the inlet to the outlet of the reactor by about 13 SC per percent by weight of copolymer in the reaction mixture (weight of copolymer by weight of solvent). Having the benefit of the above description, it would be perfectly within the ability of the art to determine the operating temperature conditions for making the copolymer according to the present invention. For example, suppose an adiabatic reactor and an exit temperature of 35 BC for a reaction mixture containing 5% copolymer. The reaction mixture will increase its temperature by approximately 13 SC per each percent by weight of copolymer, or 5% by weight x 13BC /% by weight = 65 BC. To maintain an exit temperature of 359C, a supply that has previously been cooled to 35 ° C -65 ° C = -30 ° C will be required. In the case that external cooling is used to absorb the heat of the polymerization, the input temperature of the feed could be higher and other restrictions on the temperature described above will be applicable in another way. Due to the limitations for the removal of heat and reactor temperature, the preferred maximum copolymer concentration at the outlet of the reactor is 25 weight / 100 weight of diluent. The maximum concentration that is most preferred is 15 weight / 100 weight. There is no lower limit for concentration due to reactor operability; however, for economic reasons, it is preferred to have a copolymer concentration of at least 2 weight / 100 weight. The most preferred is a concentration of at least 3 weight / 100 weight. The flow rate of the reaction mixture through the reactor should be high enough to provide good mixing of the reactants in the radial direction and reduce mixing to a minimum in the axial direction. Good radial mixing is beneficial not only for the Intra-CD and Inter-CD of the copolymer chains, but also for minimizing the radial temperature gradients due to the heat generated by the polymerization reaction. Radial temperature gradients, in the case of polymers of multiple segments, tend to broaden the molecular weight distribution of the copolymer, since the polymerization rate is faster in regions of high temperature as a result of poor heat dissipation. The architect will recognize that it is difficult to achieve these objectives in the case of highly viscous solutions. This problem can be overcome to some extent through the use of radial mixing devices, such as static mixers (for example, those produced by Kenics Corporation). It is believed that the residence time of the reaction mixture in the reactor without mixing can vary in a wide range. It is believed that the minimum could be as low as up to 0.2 seconds approximately. A preferred minimum is about 0.5 seconds. The minimum that is most preferred is approximately 1 second. It is believed that the maximum could be as large as up to 3600 seconds. A preferred maximum is approximately 40 seconds. The maximum that is most preferred is approximately 20 seconds. Preferably, the fluid flow of the polymerization reaction mass through the tubular reactor will be under turbulent conditions, for example, with a Reynolds Flow Number (NR) of at least 10,000, more preferably, at least of 50,000 and, most preferably, at least 100,000 (eg, 150,000 to 250,000) to provide the desired radial mixing of the fluid in the reactor. The Reynolds flow number is defined as: NR = DN ^ in which N 'is the fluid flow velocity (cm / sec), D' is the internal diameter of the reactor tube (cm), ^ is the density of the fluid (g / cm3) and μ is the viscosity of the fluid (poise). If desired, the catalyst activators for the selected vanadium catalysts can be used as long as they do not cause the criteria for a reactor without mixing to be violated, usually in amounts of up to 20 mol%, generally up to 5 mol%, based on the vanadium catalyst, for example, butyl perchlorocrotonate, benzoyl chloride and other activators disclosed in US Patent Applications Serial Nos. 504,945 and 50,946, filed May 15, 1987, the disclosures of which are incorporated herein by reference by reference, in its entirety. Other activators of useful catalysts include esters of halogenated organic acids, particularly alkyl trichloroacetates, alkyl tribromoacetates, ethylene glycol monoalguyl esters, (particularly, monoethyl) esters with trichloroacetic acid and alkyl perchlorocronates, and acyl halides. Specific examples of these compounds include benzoyl chloride, methyl trichloroacetate, ethyl trichloroacetate, methyl tribromoacetate, ethylene glycol monoethyl ether trichloroacetate, ethylene glycol monoethyl ether tribromoacetate, butyl perchlorocrotonate and methyl perchlorocrotonate. With reference to the accompanying drawings, particularly Figure 1, reference number 1 generally refers to a premixing device for pre-mixing the catalyst components. For purposes of illustration, it is assumed that an ethylene-propylene copolymer (EPM) will be produced with the use, as catalyst components, of vanadium tetrachloride and ethyl aluminum sesquichloride. Polymerization is a process of polymerization by adiabatic solution, with the use of hexane solvent for both the catalyst system and the reaction mixture. The premixer device 1 comprises a temperature control bath 2, a fluid flow conduit 3 and a mixing device 4 (for example, a mixing T). Mixing device 4 is supplied with hexane solvent, vanadium tetrachloride and ethyl aluminum sesquichloride through feed conduits 5, 6 and 7, respectively. Upon mixing in the mixing device 4, the resulting catalyst mixture is flowed into the conduit 3, optionally in the form of a coil tube, for a time long enough to produce the active catalyst species at the temperature set by the temperature bath . The temperature of the bath is set to provide the desired catalyst solution temperature in line 3 at the bath outlet. Upon exiting the premixer device, the catalyst solution flows through conduit 8 into the mixing zone 9 to provide intimate mixing with hexane solvent and reagents (ethylene and propylene) that are fed through conduit 10. Any device can be employed. suitable mixer, such as a mechanical mixer, orifice mixer or shock mixer. For economic reasons, the mixing T is preferred. The streams 8 and 10 are fed directly to the inlet of the reactor 12 at sufficiently high flow rates to achieve the desired level of intimate mixing. Hexane, with dissolved monomers, can be cooled upstream of the mixing zone 9 to provide the desired feed temperature at the reactor inlet. The tubular reactor 12 is provided by intermediate feeding points 13-15, where monomers (eg, ethylene and propylene as shown) and / or additional hexane can be fed into the reactor. It will be understood that the reactor can be provided with 1 or more (eg, 2-10) of these intermediate feed points). Although the reactor may be operated adiabatically, if desired or necessary to maintain the temperature of the reaction mixture within desired limits, external cooling elements, such as a cooling jacket surrounding at least a portion of the reactor system may be provided. 12. After polymerization, the polymerization is cooled rapidly (15a) at the outlet of the (or at the terminal end) reactor. This rapid cooling can be achieved by introducing water, lower alkanol or aqueous acid (for example, aqueous HCl) as a liquid into the polymerization reaction mixture (for example, in the reactor or in the affluent stream of the polymerization product). of rapid cooling per mole of V and Al total in the reaction mixture.
With reference to Figure 2, which schematically illustrates a process for mixing copolymer with lubricating oil, the rapidly cooled polymerization product from reactor 12 is fed through line 16 to an ash removal section 17, where the catalyst residues are removed from the reaction mixture in a known manner (known as ash removal). Residues of vanadium and aluminum compounds can be removed by reacting them with water to form hydroxide insoluble hydroxides and then extracting the hydroxides in dilute acid or water. If desired, other aqueous ash scavenging liquids may be employed, for example, aqueous solutions containing mineral acids (for example, HCl, HBr, HN03, H2SO4, H3P04 and the like). aqueous solutions containing mineral bases (for example, caustic ammonia, sodium methoxide and the like), or mixtures thereof. After separating the aqueous and hydrocarbon phases, for example, in a gravity settler, the polymer solution, which contains mainly solvent, unreacted monomers and copolymer products (EPM), is fed through line 18 to the mixing tank 19 of lubricating oil. Naturally, tank 19 could be a series of tanks in stages. The hot lubricating oil is fed through the conduit 20 to the mixing tank 19, where the remaining reaction mixture is heated so that the hexane and the remaining unreacted monomers are vaporized and removed through the recirculation conduit 21 through from which they flow back for reuse in the premixer device 1 after a suitable purification to remove any catalyst contaminants. The copolymer product, which is soluble in hydrocarbons, is now present in the lubricating oil and is removed from the tank 19 as a copolymer oil solution. Alternatively, the copolymer solution from the gravity settler can be steam distilled, with subsequent extrusion drying of the polymer and then mixed with a mineral oil hydrocarbon diluent to produce an oil additive concentrate or lubricating oil additive. . Having thus described the above illustrative reactor system, it will readily occur to the artisan that many variations may be made within the scope of the present invention. For example, the placement and number of multiple feeding sites, the choice of temperature profile during polymerization and the concentrations of reagents can be varied to suit the end-use application. In practicing the processes according to the present invention, the alpha-olefin copolymers having a very narrow MWD can be made by direct polymerization. Although narrow DPM copolymers can be made with the use of other known techniques, for example, by fractionation or mechanical degradation, these techniques are considered to be impractical to the extent that they are unsuitable for commercial scale operation. With respect to EPM and EPDM made in accordance with the present invention, the products have good cut stability and (with specific intramolecular CD) excellent properties at low temperatures, which makes them especially suitable for lubricating oil applications. A lubricating oil composition, according to the present invention, comprises a larger quantity of lubricating oil of base material, of lubricating viscosity, which contains an effective amount of viscosity modifier which is a copolymer of ethylene and at least one other alpha -olefin, as described in detail above. More specifically, the copolymer must have a MWD characterized by at least one of a MJM ratio. less than 2 and a ratio of Mz / M less than 1.8. The preferred ratio of M / Mn is less than about 1.6 and it is preferred that it be less than about 1.4. The preferred Mz / M is less than about 1.5 and the most preferred is less than about 1.3. It is preferred that the intra-CD of the copolymer be such that at least two portions of an individual intramolecularly heterogeneous chain, wherein each portion comprises at least 5 percent by weight of said chain, differ in composition from each other by at least 5 percent by weight of ethylene. The Intra-CD may be such that at least two portions of polymer chain differ by at least 10 percent by weight of ethylene. Differences of at least 20 percent by weight, as well as 40 percent by weight of ethylene, are considered to be in accordance with the present invention. It is also preferred that the Inter-CD of the copolymer be such that 95% by weight of the copolymer chains have an ethylene composition that differs from the composition by an average percentage by weight of ethylene of the copolymer, by 15% by weight. weight or less. The preferred Inter-CD is about 13% or less and the most preferred is about 10% or less. In a most preferred embodiment, the copolymer has all the characteristics of DPM, Intra-CD and Inter-CD that are described above, when incorporated into a lubricating oil composition or oil additive concentrate. In current practice, the ethylene-propylene copolymer is the most preferred. The preferred average ethylene content of the copolymer, on a weight basis, for use as a lubricating oil additive, is about 35% to 75%. For applications in lubricating oil additives, it is believed that the copolymer could have a weight average molecular weight as low as about 5,000. The preferred minimum is approximately 15,000 and the minimum that is most preferred is approximately 50,000. It is believed that the maximum weight average molecular weight could be as high as up to 500,000. The preferred maximum is approximately 300,000 and the most preferred maximum is approximately 300,000 and the most preferred is approximately 250,000. These limits are controlled by contemporary market requirements for cut stability. The copolymers of this invention can be employed in lubricating oils as viscosity index improvers in amounts that vary widely from about 0.001 to 49% by weight. The proportions that give the best results will vary somewhat according to the nature of the base material of the lubricating oil and the specific purpose for which the lubricant will serve in a given case. When used as lubricating oils for the crankcase of diesel or gasoline engines, the polymer concentrations are within the range of about 0.1 to 15.0% by weight of the total composition, which are effective amounts to provide modification of the viscosity and / or improvement of the IV. Normally, these polymeric additives are sold as concentrates of oil additives, in which the additive is present in amounts of about 2 to 50% by weight, preferably, about 5 to 25% by weight, based on the total amount of diluent of hydrocarbon mineral oil for the additive. The polymers of this invention are commonly employed in lubricating oils based on a mineral hydrocarbon oil having a viscosity of about 2-40 centistokes (ASTM D-445) at 1002C, but lubricating oil base materials are also considered suitable. which comprise a mixture of a hydrocarbon mineral oil and up to about 50% by weight of a synthetic lubricating oil, such as esters of dibasic acids and complex esters derived from monobasic acids, polyglycols, dibasic acids and alcohols. The finished lubricating oils, which contain the ethylene and alpha-olefin polymers of the present invention, will normally contain a number of other conventional additives in the amounts required to provide their normal concomitant functions and the foregoing include ashless dispersants, detergent additives metal or metal overbasic, zinc dihydrocarbyl-dithiophosphate (or others) as anti-wear agents, other viscosity modifiers, antioxidants, pour point reducers, lubricant oil flow improvers, corrosion inhibitors, fuel economy additives or friction reducers and Similar. Ashless dispersants include the psialyalkenyl succinimides or borated polyalkenyl succinimides, in which the alkenyl group, when derived from a C2-C10 olefin, especially polyisobutenyl, having a number average molecular weight of about 700 to 5,000. Other well known dispersants include the oil soluble polyester polyols of substituted hydrocarbon succinic anhydride, for example, polyisobutenyl succinic anhydride and the oxazoline and lactone-oxazoline oil soluble dispersants, substituted hydrocarbon-substituted succinic anhydride and disubstituted amino-alcohols. Also useful as dispersants are the long chain aliphatic hydrocarbons having a polyamine linked directly thereto and the Mannich condensation products which are formed by condensing about a molar ratio of long chain hydrocarbon substituted phenol, with about 1 to 2.5. moles of formaldehyde and about 0.5 to 2 moles of polyalkylene-psiamine, wherein the long chain hydrocarbon is a C2-C10 monoolefin polymer (eg, C2 to C5) and the polymer has a number average molecular weight of about 700 to 5,000. Lubricating oils normally contain around 0.5 to 8% by weight of ashless dispersant. Suitable metal detergent additives in the oil are known in the art and include one or more members selected from the group consisting of oil-soluble calcium, magnesium and barium phenates, overbased. sulfurized phenates, sulphonates and salicylates, especially the sulfonates of substituted benzenesulfonic acids or toluenesulfonic C 16 -C 50 alkyl, having a total base number of about 80 to 300. These overbased materials can be used as the sole metal detergent additive, or in combination with the same additives in neutral form, but the overall combination of metal detergent additives must have a basic quality represented by the previous total base number. Preferably, they are present in amounts of approximately 0.5 to 8% by weight, with a mixture of sulfurized phenate of magnesium, overbasic and sulfurized calcium phenate, neutral, which are obtained based on C8 to C12 alkyl phenols as being especially useful . Useful wear-resisting additives are zinc dihydro carbyldithiophosphate, soluble in oil, having a total of at least 5 carbon atoms, preferably C4-C8 alkyl groups or alkaryl groups of 7 to 19 carbon atoms, which are normally employed in amounts of approximately 0.5% -6% by weight. Other suitable conventional viscosity index improvers, or viscosity modifiers, are olefin polymers, such as other ethylene-propylene copolymers (e.g., those disclosed in the prior art, as discussed above), polybutene, hydrogenated isoprene or butadiene polymers, and copolymers and terpolymers of styrene with isoprene and / or butadiene, polymers of alkyl acrylates or alkyl ethacrylates, copolymers of alkyl methacrylates with N-vinyl pyrrolidone, or dimethylaminoalkyl methacrylate, ethylene polymers -propylene, post-grafted, with an active monomer such as a maleic anhydride, which can be further reacted with alcohol or an aquilene-polyamine, styrene-maleic anhydride polymers, subsequently reacted with alcohols and amines, grafted ethylene-propylene copolymers with N-vinyl-pyrrolidone, 2-vinyl-pyridine or other suitable polar monomer, or hydrogenated styrene-isoprene polymers s and hydrogenated styrene-butadiene polymers, functionalized with these polar groups, and the like. The above are employed as required to provide the desired viscosity breadth in the finished oil, according to known formulation techniques, and generally within the limitations specified in SAE J300. Examples of suitable oxidation inhibitors are hindered phenols, such as 2,6-ditertiary-butyl-paracresol, amines, sulfurized phenols and alkyl phenothiazines.In general, a lubricating oil will contain approximately 0.01 to 3 percent by weight of oxidation inhibitor, depending on its effectiveness. Corrosion inhibitors are used in very small proportions, such as approximately 0.1 to 1 percent by weight; suitable corrosion inhibitors are exemplified by the C9-C30 aliphatic succinic acids or anhydrides such as dodecenylsuccinic anhydride. The antifoaming agents are usually the polysiloxane-silicone polymers, present in amounts of about 0.001 to 1 weight percent. Pour point depressants and lubricant oil flow improvers are generally employed in amounts from about 0.01 to about 10.0% by weight, more typically from about 0.01 to about 1% by weight, for most materials base of lubricating viscosity mineral oils. Illustrative of the pour point depressants and lubricant oil flow improvers, which are commonly employed in lubricating oil compositions, are the n-alkyl-meth-acrylate polymers and copolymers and n-alkyl acrylates, the copolymers of di-n-alkyl fumarate and vinyl acetate, alpha-olefin copolymers, alkylated naphthalenes, alpha-olefin copolymers or terpolymers and styrene and / or alkyl styrene, styrene-dialkylmaleic copolymers and the like. As used herein, the following terms have the meanings indicated: thickening efficiency (SE) is defined as the percent ratio by weight of a polyisobutylene (sold as an oil solution by Exxon Chemical Company, such as Paratone N), having a Staudinger molecular weight of 20,000, which is required to thicken a neutral mineral lubricating oil, extracted with solvent, having a viscosity of 150 SUS at 37.8BC, a viscosity index of 105 and an ASTM pour point of -17.8 aC (Solvent 150 Neutral) at a viscosity of 12.4 centistokes at 98.9 aC to the percentage by weight of a test copolymer that is required to thicken the same oil at the same viscosity at the same temperature. For linear polymers of a given ethylene content, the thickening efficiency is approximately proportional to 0.75 of the weight average molecular weight energy. The low temperature properties of the lubricating oils of the present invention are evaluated by a number of tests of importance: MVR (Mini Rotary Viscometer), with the use of a technique described in ASTM-D3829, measures the viscosity in centipoise and the yielding tension in Pascais. MVR was determined at -25aC SAMF (Cold Crank Start Simulator), with the use of a technique in ASTM-D2602, the measurement of high cut viscosity, in centipoises. This test is related to the resistance of a lubricating oil to the start of a cold engine. Point of Fluency, ASTM-D97, measured in degrees centigrade. MVR cycle TP1 - It is determined by ASTM-D4684. It is essentially the same as the ASTM MVR indicated above, with the exception that a slow cooling cycle is employed. The cycle is defined in SAE Paper No. 850443, K.O. Henderson et al. The percentage of crystallinity can be measured with a variety of techniques, as defined by G. See Strate, Z.W. Wilchinsky in J. Pol. Sci. Physics. A2, 9, 127 (1971), which is incorporated herein by reference. The degree of crystallinity measured is a function of the history of annealing of the sample. Some reduced amount is desirable in this product when the sample is annealed at 20 SC for more than 48 hours after the preparation of a void-free, stress-free specimen, heating at 50 ° C for 30 minutes in a suitable mold. It is well known that homogeneous Intra-CD EP copolymers, made with vanadium catalysts, are made semi-crystalline in the region of 55-65% by weight of ethylene. (See the Encyclopedia of Polvmer Science, cited earlier, in Figure 5). In case one of the segmented polymers of the present invention exhibits a finite degree of crystallinity, the crystallinity must arise from that portion of the chain having a high ethylene content. When it is not possible to independently measure the crystallinity in a segment of a chain when it is connected to non-crystalline portions. It should be inferred that the crystallinity arises from the portions with high ethylene content. The cut stability index (IEC) measures the mechanical stability of the polymers used as I.V. in crankcase lubricants, subject to high stress regimes. The diesel fuel injector test was used (CEC L-14-A-79; equivalent to DIN 51382). To determine the IEC, the polymer under test was dissolved in a suitable base oil (for example, 150 neutral extracted with solvent) at a relative viscosity of 2 to 3 at 100 aC. The solution in oil is then circulated through a diesel fuel injector, for a total of thirty passes. The IEC is calculated based on the initial kinematic viscosity at 100 aC (Vj) the final kinematic viscosity (Vf) and the viscosity of the base oil (Vb), as IEC (%) = 100 x (V - Vf) / (Vi ~ Vb) - A reference sample (as required by the DIN method) is used to calibrate the test. Filtration Capacity - Cummins-Fleetguard Water Tolerance Test, as defined in SAE Document No. 870645. The test requires filtration of 200 ml. of a formulated oil, at room temperature, through the filter for automobiles with a pore size of 5 microns. The step performance is obtained with flow rates of at least 4 ml / min. with a maximum filter weight gain of 20 mg. In the following examples, ~ M, and Mz / M were determined by GPC / LALLS with the use of a total diffuse light intensity in 1, 2, 4-trichlorobenzene at 135 ° C, with the use of a Chromataix diffuser photometer KMX-6; the specific refractive index increase dn / dc is -.104 (g / cc) -l. The M Mn values were determined based on a solution-to-molecular weight time relationship as stated in the specification, data accuracy of + .15. The ethylene content (% by weight) was determined with the use of infrared analysis by Method A ASTMA D-3900, accurate to + 2% ethylene. The composition distribution was determined in fractions comprising 5-20% of the weight of the original polymer; hexane / isopropyl alcohol is used as a solvent / non-solvent pair. The Inter-CD is determined as the composition width which includes 95% by weight of the polymer. Intra-CD is determined by fragmenting the chains to approximately 5% of their original molecular weight. Intra-CD is also determined as the difference in composition between the fractions with the highest ethylene content of the original and fragmented chains and among the most reduced of these fractions. Is Intra-CD also evaluated based on adiabatic polymerization? T, the reactivity ratios and the heats of polymerization as provided in the description. EXAMPLE 1 FOR COMPARISON In this example, a series of ethylene-propylene copolymers with different ethylene content was prepared in a conventional continuous flow stirred tank reactor. These polymers are typical of the viscosity modifier technology of the prior art. The above serve as reference data. (Copolymer samples in Passes 1-3 and 1-4 can be obtained commercially). The catalyst, the monomers and the solvent were fed to an 11.35 liter reactor with regimes shown in Table I attached. The hexane was purified before use by passing over 4A molecular sieves (Union Carbide, Linde Div., Granules 4A of 0.158 cm) and silica gel (WR Grace Co., Chemical Div. Division, PA-400, Mesh 20-40 to remove polar impurities that act as catalyst contaminants Gaseous propylene and ethylene were passed over hot Cu20 (270aC) (Marshaw Chemical Co., CU1900, 0.635 cm spheres) to remove oxygen, with subsequent treatment with molecular sieves ( as before) for water removal The monomers were then combined with the hexane upstream of the reactor and passed through a cooler which provided a sufficiently low temperature to completely dissolve the monomers in the hexane.The polymerization temperature was controlled by adjusting the feed temperature and running the reactor adiabatically, the feed absorbed the heat of reaction generated by the polymerization. output from the reactor was controlled at 413 kPa to ensure the dissolution of the monomers and a reactor filled with liquid. The catalyst solution was prepared by dissolving 37.4 g. of VC14 in 7 1. of purified n-hexane. The co-catalyst consisted of 96.0 g of Al2Et3Cl3 in 7 1. of n-hexane. These solutions were fed to the reactor with regimes shown in Table IA. In the case of pre-mixed catalysts, the two solutions were premixed at 0 ° C for 10 seconds before entering the reactor. The copolymer was subjected to ash removal by contacting it with dilute aqueous HCl and was recovered by steam distillation of the diluent with mill drying of the product to remove residual volatile elements. The polymers were stabilized with 0.1% by weight of Irganox 1076, an hindered phenol antioxidant (Ciba Geigy). The product prepared in this way was performed to determine the composition and molecular weight distribution with the use of the techniques set forth in this description. The results were like those in Table IA. The copolymers were of an essentially homogeneous composition, with heterogeneity of + 3% with respect to the average, that is, approximately within the experimental error of being completely homogeneous. These results indicate that, for the copolymer made in a continuous flow stirred reactor, the Mp / Mn was approximately 2. As in a reactor with mixing system in the back the monomer concentrations are constant, the Intra-CD was less than 5% ethylene. The premixing of catalysts and the presence of hydrogen have no effect on the Mp / Mn in a reactor with mixing system in the back. Experiments at an amplitude of polymerization conditions, with the same catalyst system, produced polymers of similar structure. (In the examples "sesqui" means ethylaluminum chloride). TABLE IA Copolymer Copolymer Copolymer Copolymer Passed 1-1 Passed 1-2 Passed 1-3 Pass 1-4 Temp. (AC) Feed- -30 -25 -40 -40 Reactor Temp. (aC) Reac- 35 35 55 38 tor Reactor Feed Regimes * = (g / 100 g, hexane) Hexane (kg / hr) 40 40 38 48 Ethylene (*) 3.4 3.4 5.4 3.0 Propylene (*) 2.9 2.4 5.0 10 VOCl3 / sesqui (*) .0095 .0095 .011 .01 Al / V (molar) = 5: 1 5: 1 5: 1 5: 1 H2 ppm at C2 25 15 100 50 Permanence time10 10 11 8 Reactor (minutes) Concentration 6.0 5.7 7.3 7.0 cement (g / 100 g hexane) Catalyst efficiency 635 600 700 700 Zador (polymer g / g. V0C13) (Mp) x lO4 1.55 1.5 1.3 1.55 (Mz / Mp) 1.8 1.8 1.8 1.8 Average composition 52 58 67 43 % by weight ethylene) Distribution of + 3 + 3 + 3 + 3 intermolecular composition (%) Crystallinity (%) 0 0 1 0 (? Hf cal / gx 100) 69 The CFSTR copolymers prepared in this way were then tested to determine their viscometric properties, dissolving 0.95 g of each copolymer in 100 g of mineral oil of base material S150N (Mid-Continent) containing 0.4% by weight of a commercial lubricating oil pour point depressant (vinyl fumarate acetate; Paraflow 449, Exxon Chemical Co.) to make SAE 10W-40 oils. The resulting lubricating oil compositions were then tested to determine the CCS viscosities (at -20aC) and viscosities MVR (at -25aC). The data obtained in this way is summarized in Table IB below. TABLE IB Passed NO% ethylene weight TE CCS MRV Point Fluency - (CP) (CP) (° - C) 1-1 52 2.8 VE 32,000 -26.1 1-2 58 2.8 VE > 106 -12.2 1-3 67 3.0 VE 15,000 -12.2 1-4 43 2.8 3100 20,000 -31.7 - IB (Continued) Pass No SSI Filtering Capacity 1-1 Pass 41 1-2 Pass 37.5 1-3 Failure 32.5 1-4 Pass 48 In the table above, "VE" (as defined in ASTM D2602) means that the copolymers showed a strong viscoelastic response in the SAMF test, making it impossible to determine the SAMF viscosity. The above is unacceptable for IV breeders. Polymers 1-1 and 1-2 have unacceptably high MVR viscosities. The requirements of SAE J300 for 10W-X oils is an MVR viscosity of less than 30,000 cP at -252C. Polymers 1-1. 1-2 and 1-3 have all unacceptably high pour points; 10W-X oils must have a pour point of -30 aC. The oil prepared on the basis of Sample 1-3 does not pass the Cummins-Fleetguard filter test because it completely obstructs the filter after only 8 ml have been filtered. of oil. It is evident, based on these properties, that polymers of conventional technology, with an average ethylene content of more than 5% by weight, are not acceptable as viscosity modifiers.
EXAMPLE 2 FOR COMPARISON This example demonstrates the effect of ethylene content on EE-IEC, SAMF, MVR and the performance of filtering capacity. All polymers were prepared in a reactor with mixing system in the back and the data are expressed in Table II below. Figure 5 shows the convenience of having a high ethylene content in EE-IEC. Figure 6 shows the convenience of having a high ethylene content in CCS. Thus, if ways of preparing copolymer with more than 50% by weight of ethylene can be found, these EE-IEC and SAMF benefits will be achieved, if the VE effect can be avoided. A high EE for a given IEC is convenient, since the polymer is more effective for thickening the oil than with low EE. EXAMPLE 3 FOR COMPARISON This example illustrates the improvement of the viscometric properties that are obtained when preparing a Narrow DPM, Narrow Intra-CD copolymer, according to the North American Patent No. 4,540,753. The polymerization reactor had a tube 10 meters long and 2.67 cm internal diameter. The monomers, the hexane, the catalyst and the whole catalyst were continuously fed to the reactor at one end and the monomers without react they withdrew from the other end. The monomer side streams were introduced at selected points along the tubular reactor. The monomers were purified by conventional distillation methods and the reactor temperature was controlled as in Example 1. The reactor pressure was controlled to approximately 5 bars (calibrator) by regulating the downstream pressure of the catalyst ash removal facilities. A catalyst solution was prepared by dissolving vanadium tetrachloride, 18.5 g. VC14 in 5 liters of purified n-hexane. The co-catalyst consisted of 142 g. of ethyl. TABLE II Passage No Ethylene TE% KO SSI Exxon S150NRP% Weight CCS: cP MVR; cP 2-1 39 2.40 39.6 3 3552200 1 177,, 220000 2-2 41 2.27 38.9 3 3660000 1 188,, 220000 2-3 45.6 2.44 39.9 3 3440000 2 222,, 330000 2-4 50.7 2.58 39.5 3 3880000 2 211,, 660000 2-5 53.1 2.69 40.4 3 3880000 1 188,, 440000 2-6 54.5 2.01 39.9 V VEE mmásás ddee 110066 2-7 61.5 2.92 40.4 VE more than 10 ° 2-8 66.5 3.0 32.5 2400 30,000 (YS) 2-9 44 2.8 48 3300 20,000 aluminum sesquichloride, Al2Et3Cl3, in 5.0 liters of purified n-hexane. In the case of the premixing of catalysts, the two solutions were premixed at a given temperature (as indicated in Table IIIA) for 8 seconds before entering the reactor. Table IIIA includes the feed rates for monomers, catalyst and residence times. The polymer was recovered and analyzed as in Example 1. The composition distributions were calculated with the use of the reactor temperature profile as described in the description and are schematically illustrated in Figures 7-13 for Past 3-1. to 3-7, respectively. The copolymers were dissolved in the same mineral oil as in Example 1 to formulate again 10W-40 oils. The viscometric properties determined in this way are summarized in Table IIIB below. TABLE IIIA (Ex. 3) Example No (Key Sample No) 3-1 3-2 3-3 3-4 3-5 3-6 Temp. Reac Input 25 25 20 20 21 22 tor (aC) Temp. Output Reac- 47 45 46 48.5 36 47 tor (aC) Temp.Alimentation 3 4 14 5 5 5 lateral current (aC) Temp. Premixed 14 14 13.5 12 14 14 Catalysts (2C) Pre-mixed time 8 8 catalysts (sec) Reactor Permanence Time (sec) in Sidestream 1 43 .43 .84 .40 .85 .84 Lateral current 2 81 .81 1.53 .74 1.53 1.51 Lateral current 3 1.1 166 1.16 2.22 1.05 2.18 2.14 Perm. Reactor 2.1 1 2.1 4.1 1.30 3.09 3.05 in rapid cooling (sec). Inlet feed rates (kg / hr) Hexane 2480 2437 2456 2200 2400 2430 Ethylene 13.2 13.2 11.2 28.8 15.5 17.6 Propylene 58.2 67.5 54 230 141 141 VC14 .19 .128 .125 .175 .169 .248 A12 (C2H5) 3C13 .98 .66 .63 .90 .87 1.27 Hexane Sweep (kg / hr)) ^ 83 84 110 100 100 Regimes Feeding Lateral stream (kg / hr) Hexane 440 480 460 710 870 840 Ethylene 30 30 33.6 55 32 49 Propylene 30 30 33.6 55 32 49 Total Hexane (kg / hr) 3000 3000 3000 3020 3170 3170 Divisions Feed Side currents (% weight) Sidestream 1 30 30 24 30 30 33 Lateral Current 2 35 35 37 35 35 33 Lateral Current 3 35 35 39 35 35 33 Rapid cooling 1.4 3 3 3 3 3 (kg / hr) -ethanol Mp (xlO *) 115 140 165-200 185 180 (2) 160 ( Mz / Mp 1. 15 1. 115 1. 2 1. 15 - Composition (% ethylene weight) 65 64 64 60 58 57 Crystallinity 6 6 4 2 3 (A Hf cal / g x 100) 3) 69 E. No (Key SampleNo) 3-7 Temp. Reactor inlet (° C) 18 Temp. Reactor Output (° C) 35 Temp.Supply Lateral Current (° c) 1 Temp. Premixed Catalyst (° c) 13 Premixed Time Catalyst (sec.) 8 Permanence Time in Reactor (sec) in Lateral Current 1. 34 Sidestream 2. 55 Sidestream 3. 43 Time Remaining in Cooling Reactor .99 Fast (sec.) Input Power Regimes (kg / hr) Hexan 2275 Ethylene 32.4 Propylene 262 VC14 .31 A12 (C2H5) 3C13 1.6 Hexane Sweep (kg / hr) a > 59 Regimes Feeding Lateral stream (kg / hr) Hexane 900 Ethylene 38.4 Propylene 38.4 Total Hexane (kg / hr) 3275 Divisions Feeding Lateral Current (% weight) Lateral Current 1 28 Sidestream 2 37 Lateral Current 3 35 Rapid cooling (kg / hr) -ethanol 3 Mp (xlO3) 110 Mz / Mp 1.1 Mp / Mn 1.21 Composition (% ethylene weight) 61 Crystallinity (? Hf cal / g x lOO) 3) 2 69 NOta: (1) Scanning hexane introduced with the catalysts (2) Estimated based on EE. (3)% by weight. All these samples were prepared with a high ethylene content (more than 50% by weight of average ethylene content), in which conventional technology failed. The narrow MPD obviously improved the EE-IEC ratio, as can be seen by comparison with Figure 5. For example, samples 3-2 and 3-3 have the same average ethylene content, 64% by weight, and interpolation between their respective EEs show that the EE with 40% IEC can be increased by approximately 0.2 units of EE, due to the narrowing of DPM. Sample 3-7, with 55% by average ethylene weight, shows a similar EE-IEC credit. With respect to the properties at low temperatures, the narrow DPM and the narrow Intra-CD show an improvement in the performance of CCS. Samples 3-5, 3-6 and 3-7 do not show the viscoelastic effect, while the conventional technology of Comparative Example 2 (Samples 2-6 and 2-7) does show it. In general, the MVR viscosities also improve with several pass values. However, none of these samples from Comparative Example 3 showed being able to pass the pour point test. The data indicate that to pass the filtration capacity test, the average ethylene content should be less than 60-64% by weight. It is concluded that the homogeneous Intra-CD is unacceptable to satisfy all the performance criteria.
EXAMPLE 4 This example illustrates the improved properties that are obtained by the novel segmented copolymers of this invention. With the use of the procedure of Comparative Example 3 and the use of the conditions summarized in Table IVA, a series of copolymers was prepared. The polymers were recovered and analyzed as in Comparative Example 1. The contours of the copolymer chains are illustrated for Runs 4-1 and 4-2 in Figures 14 and 15, respectively. Each copolymer was then dissolved in the pour point base depressant material mixture described in Example 1. The resulting lubricating oil compositions were tested and the data thus obtained is expressed in Table IVB. TABLE IIIB ^ 1) Past Ethylene EE SAMF MVR Capacity Point SSI No.% weight (cP) (CP) Filter fluidity (aC) of 3-1 65 2.7 2400 10,000 -28.9 Not passed 26 3-2 64 3.2 2400 10,500 -26.1 Did not pass 37 3-3 64 3.8 2450 8,600 -26.1 Did not pass 48 3-4 60 3.9 VE 30,000 -26 Passed 61 3-5 58 3.8 2300 43,000 -12 Passed 58 3-6 57 3.4 2500 12,000 -20 Passed 57 3-7 55 2.7 VE 47,000 -20 31 -_ (YS > 140Pa) (1) All in base material Exxon as in Example 1. (2) Cycle TP1. TABLE VAT (e 4. No (Key Sample No) Temp Reactor Input 19.5 -36.7 22 (aC) Temp Reactor Output (aC) 46 12.8 27 44 Supply Temp. Current 5 -31.7 4 6 Lateral (aC) Temp. Premixed Cataliza14.5 15.6 15 15 (aC) Pre-mixed Time Catalyst (sec) Time Remaining in Reactor (sec.) In Sidestream 1 .68 1.27 67 1.7 Lateral current 2 .84 1.41 Permanence time in 2.2 2.5 14.3 2.1 Cooling reactor fast (sec.) Regimes Inlet feed (kg / hr) Hexane 1828 165 2710 2100 Ethylene 18 1.16 17.3 37 Propylene 270 17.5 86.4 280 vc? 4 .288 .020 .13 .29 A12 (C2H5) 3C13 1 .24 .522 .65 1.49 Hexane Sweeping 102 5.6 103 116 (kg / hr) (1) Feeding regimes Lateral current (kg / hr) (2) Hexane 1092 27 355 1000 Ethylene 49.2 1.1 3.5 44 Propylene 49.2 4.9 110 44 Total Hexane (kg / hr) 33020 192 3170 3100 Divisions Food Side Currents (% weight) C Coorrrriieennttee llaati: eerraall 1 1 6 600 7 711 100 100 C Coorrrriieennttee llaatteerraall 2 2 4 400 2 299 __ _._ Mp (xlO3) 180 170 165 160 M2 / Mp 1.2 1.1 1.25 Composition (wt% ethylene 53 55 53 55 log) Fast cooling (kg / hr) Ethanol 4.5 102 14.3 H20 Crystallinity 2 1 2 (4) 2 (4) (A Hf cal / g. X 100) 69 (%) Notes: (1) Scanning hexane introduced with catalysts (2) Total flows of equal side streams, except where indicated. (3) Made in a 12.7 cm reactor, feed rates in k lb / hr. (4) It was observed that these samples had rigidity at ambient temperature, which indicates that the samples contained some crystallinity. It was not measured? Hf. TABLE IVB Passed Ethylene EE SAMF MVR Fluid point IEC Capacity No.% weight (cP) (cP) dez (aC) of filtering 4-1 53 3.6 2750 10,000 -34.4 Passed 52 4-2 55 3.6 2750 12,000 - 35.3 Passed 48 These samples with the TMT segment distribution produce an improved balance of all the properties. CCS and MVR are acceptable, as they were for several of the homogeneous samples of Comparative Example 3. However, the pour points are now acceptable and polymers with acceptable pour point and filterability are obtained (Samples 4-1 and 4). -2) . The crystallizable "M" segment produces low viscosity, while the non-crystallizable "T" segments inhibit the formation of gels that provide high pour points, viscosity or high yield stress in MVR and poor filtering capacity. EXAMPLE 5 This example illustrates the preparation of copolymers containing one M segment and a segment T. The procedure of Comparative Example 3 was repeated using the conditions set out in Table IVA. The resulting lubricating oil compositions gave the data which is expressed in Table V. TABLE V Passed Ethylene EE SAMF MVR IEC Capacity No. Weight% (cP) (cP) filtered fluidity j- ^ Cj 5-1 53 3.3 2900 12, 000 -31.7 Passed 54 The copolymer of this example (whose chain contour is illustrated in Figure 16) also clearly provides improved viscoetric properties compared to the copolymers of Comparative Example 1, in a manner completely similar to Example 4. This MT segment polymer shows improved properties with respect to the conventional technology of Comparative Examples 1 and 2 and the homogeneous, narrow DPM polymers of Comparative Example 3.
Example 6 In this example, a segmented structure is prepared, as in Example 4, except that the high content and low content portions of the chain are exchanged, so that the ends have a high ethylene content and the center has a low content. (The conditions for the preparation of this polymer are expressed in the Table IVA above). Corresponds to an M-T-M structure (Structure IV, as explained above). The average composition is the same as in Example 4-1, 53% by weight of ethylene. The chain contour of this copolymer is illustrated in Figure 17. The copolymer was dissolved in the pour point base depressant material mixture, which is described in Example 1. The results are tabulated in Table VII to continued: Table VII Passed Ethylene EE SAMF MVR MVR Fluid point No Weight (cP) (cP) Tension dez 9C Alternate (Pa.) 8-1 53 3.25 2780 29,000 140 -32 This polymer is inacepetable as a commercial viscosity modifier , because it shows a measurable strain or yield stress in the MVR, as well as a high MVR viscosity. The two crystallizable sections in the polymer molecules allow the formation of a weak network in MVR at low temperatures, which looks solid, capable of supporting a finite effort before the flow is established (the so-called yielding effort), above which , the network breaks and the oil is again fluid, although with a much higher viscosity than in Example 4-1. The copolymers of the present invention are also useful in automotive applications and industrial mechanical products, due to their excellent resistance to environmental conditions, good thermal aging properties and the ability to form compounds with large amounts of fillers and plasticizers, which gives As a result, low cost compounds. Therefore, the polymers of this invention can be entangled with peroxide initiators, or with radiation to produce polymer networks, due to their narrow DPM they have good performance properties. The typical uses in automobiles are in the sidewalls of the rims, internal chambers, radiator hoses and heaters, vacuum piping, weather stripping and sponge seals for doors. Uses in typical mechanical products are for apparatus hoses, garden and industrial hoses, both molded and extruded sponge parts, gaskets and seals, and conveyor belt covers. These copolymers are also useful in adhesives, parts of apparatus such as hoses and packaging, wires and cables and mixtures of plastics.

Claims (12)

  1. Based on the above description, a person skilled in the art can determine the essential characteristics of this invention and, without departing from the spirit and scope thereof, make various changes and modifications of the invention to adapt it to various uses and conditions. NOVELTY OF THE INVENTION Having described the invention, it is considered as a novelty and, therefore, the ownership of the content is claimed in the following: CLAIMS 1. A composition of oil additive concentrate, comprising mineral oil diluent of hydrocarbon and about 2 to 50% by weight, based on the total amount of hydrocarbon mineral oil diluent, of a copolymer of ethylene and at least one other alpha-olefin, wherein said copolymer has a DPM which is characterized by at least by a ratio of Mp / Mn less than 2 and a Mz / Mp ratio of less than 1.8, and wherein said copolymer comprises intramolecularly heterogeneous polymer chains containing at least one crystallizable segment of methylene units and at least one ethylene-alpha-olefin copolymer segment of low crystallinity, wherein said crystallizable segment comprises at least 10 percent by weight of said copolymer chain and has an average ethylene content of at least about 57 weight percent, wherein said low crystallinity segment includes an average ethylene content of about 20 to 53 weight percent, and that at least two portions of a chain Individual intramolecularly heterogeneous, in which each portion comprises at least 5 weight percent of said chain, differ in composition from one another by at least 7 weight percent ethylene. The oil additive concentrate composition according to claim 1, wherein said dispersion of intermolecular composition of said copolymer is such that 95 percent by weight of said copolymer chains has a composition 13%, or less, different of said average ethylene composition. 3. The oil additive concentrate composition according to claim 2, wherein said copolymer has a weight average molecular weight of about 50,000 to 500,000. 4. The oil additive concentrate composition according to claim 3, wherein said weight average molecular weight is less than about 300,000. 5. The oil additive concentrate composition according to claim 4, wherein said weight average molecular weight is less than about 250,000. 6. The oil additive concentrate composition according to claim 5, wherein said copolymer comprises ethylene and propylene. The oil additive concentrate composition according to claim 1, wherein said copolymer has a total maximum ethylene content of about 90% on a base by weight. The oil additive concentrate composition according to claim 1, wherein said copolymer has a MWD that is characterized by at least one of a Mp / Mn ratio of less than about 1.5 and a ratio of Mz / Mp. less than about 1.5. 9. The oil additive concentrate composition according to claim 1, wherein said copolymer has a DPM that is characterized by at least a Mp / Mn ratio of less than about 1.25 and a lower Mz / Mp ratio of approximately 1.2. 10. The oil additive concentrate composition according to claim 1, wherein said copolymer has a DPM that is characterized by at least a ratio of Mp / Mn less than about 1.5 and a ratio of Mz / Mp less than 1.5 and wherein said copolymer has a dispersion of intermolecular composition such that 95 percent by weight of said copolymer chains have a composition 13% by weight, or less, different from said average ethylene composition. 11. An oil additive concentrate composition according to claim 10, wherein said dispersion of intermolecular composition is such that 95 weight percent of said copolymer chains has a composition 10% by weight, or less, different from said composition. of average ethylene. 12. An oil additive concentrate composition according to claim 1, wherein said copolymer has a DPM which is characterized by at least an Mp / Mn ratio of less than about 1.25 and a lower Mz / Mp ratio of about 1.2, and wherein said copolymer has a dispersion of intermolecular composition such that 95 percent by weight of said copolymer chains has a composition 13% by weight, or less, different from said average ethylene composition. IN WITNESS WHEREOVER, I sign this description and clauses in this City of Mexico, D.F., on the 20th day of May, 1988.
MXPA/A/1994/000838A 1987-07-13 1994-02-01 Viscosity modifier polymers MXPA94000838A (en)

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