WO2015094580A1 - Procédé de production d'un polymère fonctionnalisé - Google Patents

Procédé de production d'un polymère fonctionnalisé Download PDF

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WO2015094580A1
WO2015094580A1 PCT/US2014/066876 US2014066876W WO2015094580A1 WO 2015094580 A1 WO2015094580 A1 WO 2015094580A1 US 2014066876 W US2014066876 W US 2014066876W WO 2015094580 A1 WO2015094580 A1 WO 2015094580A1
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polymer
mol
functionalized
functionalized polymer
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WO2015094580A9 (fr
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Yong Yang
Jay L. Reimers
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Exxonmobil Chemical Patents Inc.
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08C—TREATMENT OR CHEMICAL MODIFICATION OF RUBBERS
    • C08C19/00—Chemical modification of rubber
    • C08C19/08—Depolymerisation
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F8/00—Chemical modification by after-treatment
    • C08F8/06—Oxidation
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/10—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation

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  • This invention relates to processes to produce functionalized polymers using iodine modified polymer and uses of such functionalized polymers.
  • Hydrocarbon polymers and oligomers with polar end groups are very important and useful building blocks for many chemical syntheses and processes.
  • many applications of these polymers and oligomers are hindered by the limited availability of such functional polymers and oligomers.
  • telechelic hydrocarbon polymers are based on polybutadienes, which are produced by a radical process to generate hydroxyl groups at both the chain ends. Further chemical reactions can convert the hydroxyl groups to some other functional groups such as carboxylic acids, amines and isocyanates.
  • these processes have poor controllability and tunability.
  • oxidative cleavage of alkenes is "Oxidative Cleavage of Alkenes Using an In Situ Generated lodonium Ion with Oxone as a Terminal Oxidant", Prem P. Thottumkara and Thottumkara K. Vinod; Organic Letters 2010, 12, pp. 5640-5643.
  • a process to produce a functionalized polymer comprises:
  • a process to produce a functionalized polymer comprises:
  • the polymer having internal or terminal unsaturation can be a polyolefin.
  • Suitable polyolefins include polydienes or a vinyl/vinylidene terminated macromonomer (VTM).
  • a process to produce a functionalized polymer comprises contacting a first polymer comprising a vinyl or vinylidene terminated macromonomer (VTM), having an M n of at least 50 g/mol, more particularly at least 500 g/mol, and even more particularly at least 1000 g/mol as determined by GPC with an oxidizing agent comprising an iodine containing compound and an optional phase transfer catalyst to obtain the functionalized polymer.
  • VTM vinyl or vinylidene terminated macromonomer
  • the functionalized polymer from the starting polyolefin has an M n less than the M n of the starting polyolefin and the functionalized polymer has an acid number higher than the acid number of the original polyolefin.
  • FIG. 1 is a 'H NMR spectrum of hydrogenated and cleaved polymer from Example 1.
  • FIG. 2a is a GPC-3D of hydrogenated PBd from Example 1.
  • FIG. 2b is a GPC-3D of hydrogenated and cleaved polymer from Example 1.
  • FIG. 3 is a 3 ⁇ 4 NMR spectrum of hydrogenated and cleaved polymer from Example 2.
  • FIG. 4 is GPC of hydrogenated and cleaved polymer from Example 2.
  • a "Group 4 metal” is an element from Group 4 of the Periodic Table, e.g. Hf, Ti, or Zr.
  • an "olefin,” alternatively referred to as “alkene,” is a linear, branched, or cyclic compound of carbon and hydrogen having at least one double bond.
  • alkene is a linear, branched, or cyclic compound of carbon and hydrogen having at least one double bond.
  • a copolymer when a copolymer is said to have an "ethylene" content of 35 wt% to 55 wt%, it is understood that the mer unit in the copolymer is derived from ethylene in the polymerization reaction and said derived units are present at 35 wt% to 55 wt%, based upon the weight of the copolymer.
  • a "polymer” has two or more of the same or different mer units.
  • a “homopolymer” is a polymer having mer units that are the same.
  • a “copolymer” is a polymer having two or more mer units that are different from each other.
  • a “terpolymer” is a polymer having three mer units that are different from each other.
  • oligomer is typically a polymer having a low molecular weight (such an M N of less than 25,000 g/mol, preferably less than 2,500 g/mol) or a low number of mer units (such as 75 mer units or less, preferably 25 mer units or less).
  • ethylene polymer or "ethylene copolymer” is a polymer or copolymer comprising at least 50 mole% ethylene derived units
  • a "propylene polymer” or “propylene copolymer” is a polymer or copolymer comprising at least 50 mole% propylene derived units, and so on.
  • ethylene shall be considered an a-olefin.
  • M n is number average molecular weight
  • M w is weight average molecular weight
  • M z is z average molecular weight
  • wt% is weight percent
  • mol% is mole percent.
  • Molecular weight distribution (MWD) also referred to as polydispersity, is defined to be M w divided by M n . Unless otherwise noted, all molecular weight units (e.g., M w , M n , M z ) are g/mol.
  • an ethylene polymer having a density of 0.86 g/cm 3 or less is referred to as an ethylene elastomer or elastomer; an ethylene polymer having a density of more than 0.86 to less than 0.910 g/cm 3 is referred to as an ethylene plastomer or plastomer; an ethylene polymer having a density of 0.910 to 0.940 g/cm 3 is referred to as a low density polyethylene; and an ethylene polymer having a density of more than 0.940 g/cm 3 is referred to as a high density polyethylene (HDPE).
  • HDPE high density polyethylene
  • density is measured by density-gradient column, as described in ASTM D1505, on a compression-molded specimen that has been slowly cooled to room temperature (i.e., over a period of 10 minutes or more) and allowed to age for a sufficient time that the density is constant within +/- 0.001 g/cm 3 .
  • the units for density are g/cm 3 .
  • Polyethylene in an overlapping density range i.e., 0.890 to 0.930 g/cm 3 , typically from 0.915 to 0.930 g/cm 3 , which is linear and does not contain long chain branching, is referred to as "linear low density polyethylene” (LLDPE) and can be produced with conventional Ziegler-Natta catalysts, vanadium catalysts, or with metallocene catalysts in gas phase reactors and/or in slurry reactors and/or with metallocene catalysts in solution reactors.
  • LLDPE linear low density polyethylene
  • mLLDPE is an LLDPE made by a metallocene catalyst.
  • Linear means that the polyethylene has no long chain branches; typically referred to as a g' vis of 0.95 or above, preferably 0.97 or above, preferably 0.98 or above, preferably 0.99 or above, preferably 1.0.
  • Composition Distribution Breadth Index is a measure of the composition distribution of monomer within the polymer chains and is measured by the procedure described in PCT publication WO 93/03093, published Feb. 18, 1993, specifically columns 7 and 8, as well as in Wild et al, J. Poly. Sci., Poly. Phys. Ed., Vol. 20, p. 441 (1982) and U.S. Patent No. 5,008,204, including that fractions having a weight average molecular weight (M w ) below 15,000 g/mol are ignored when determining CDBI.
  • M w weight average molecular weight
  • Me is methyl
  • Et is ethyl
  • Pr is propyl
  • cPR is cyclopropyl
  • nPr is n-propyl
  • iPr is isopropyl
  • Bu is butyl
  • nBu is normal butyl
  • iBu is isobutyl
  • sBu is sec -butyl
  • tBu is tert-butyl
  • Oct octyl
  • Ph is phenyl and Bn is benzyl.
  • room temperature is 23 °C.
  • This invention discloses the production of hydrocarbon polymers or oligomers with polar end groups from their hydrocarbon precursors that contain alkenes, preferably internal alkenes or terminal alkenes, by selective oxidative cleavage.
  • the hydrocarbon precursors with alkenes can be linear polymers such as polybutadienes or polyisobutylene.
  • the alkenes in the hydrocarbon precursors can also be generated by thermal or peroxide degradation of polyolefm (such as polyethylene)-based olefin homo- or co-polymers.
  • the polyolefm is an ethylene copolymer comprising ethylene and one or more of propylene, butene, pentene, hexane, octene, nonene, decene, undecene, dodecene and/or other alpha-olefins or diolefins.
  • a benefit of using controlled degraded olefin copolymers as starting materials is that it delivers fully saturated functional polyolefins, avoiding the extra hydrogenation step if polybutadienes are used as the starting materials.
  • the product can have polar functional group at one chain end, or more preferably polar functional groups at both chain ends, giving rise to a telechelic hydrocarbon polymer.
  • the polar functional groups can be, but are not limited to, carboxylic acid, carboxylate, aldehyde, ketone and alcohol, depending on the oxidant species and dosage.
  • the molecular weight of the product, for some cases such as using polybutadienes as the starting materials, can also be determined by the stoichiometric amount of oxidant used.
  • Hydrocarbon polymers with polar end groups, especially telechelic polymers are useful building blocks for further chemical syntheses and processes.
  • the method described in this invention has the advantage of conveniently producing such functional polymers as needed.
  • the molecular weight and other properties of the product can be controlled during the oxidative cleavage process, mainly by the catalysis, oxidant species and feeding ratio.
  • the method in this invention uniquely and conveniently gives access to many functional polymers, especially telechelic polymers, which are not available by current processes.
  • a potential application of the telechelic polymers is to build up dendritic structures by reacting the telechelic polymers with multifunctional connecting molecules.
  • the chemical reaction and terminal application set up the requirements for the telechelic polymers.
  • this invention relates to the production of hydrocarbon polymers with polar end groups from their hydrocarbon precursors that have an M n of at least 50 g/mol, more particularly at least 500 g/mol, and even more particularly at least 1000 g/mol as determined by GPC and contain terminal alkenes (such as allyl chain ends, specifically vinyl groups) and by contacting the polymer having the terminal alkene with oxidizing agent comprising an iodine containing compound and optional phase transfer catalyst and obtaining functionalized polymer, and optionally hydrogenating the functionalized polymer.
  • oxidizing agent comprising an iodine containing compound and optional phase transfer catalyst
  • this invention relates to a process to produce a functionalized polymer comprising:
  • this invention relates to a process to produce a functionalized polymer comprising:
  • the functionalized polymer has an M n less than the M n of the starting polymer (preferably at least 10% less than, preferably at least 25% less than, preferably at least 50% less than) and the functionalized polymer has an acid number higher than the acid number of the starting polymer, preferably at least 20% higher, preferably at least 50% higher, preferably at least 100% higher.
  • the iodine modified aromatic polymers preferably comprise an iodophenyl group on the crosslinked or non-crosslinked polymers, preferably aromatic polymers.
  • the iodine modified polymers typically contain approximately 0.001 wt% to 10 wt% of iodo groups to the weight% of the polymer, more preferably in the range of 0.01 wt% to 5 wt%, most preferably in the range of 0.05 wt% to 2 wt%.
  • the iodine modified polymers are typically utilized in oxidation/functionalization reactions described herein over temperature range of -100°C to 300°C, preferably in the range of -50°C to 200°C, more preferably in the range of 0°C to 100°C.
  • Complexing agents include a metal or organometallic complex that is able to bind to an alkene.
  • the complexing agents are RuC3 ⁇ 4, Os0 4 , PhCOOAg, AgOAc, Pd(OAc)2, Pd(dba) 3 , ⁇ (3 ⁇ 4, ⁇ (3 ⁇ 4 etc.
  • the complexing agent is typically impregnated or bound to a solid support in the range of 0.0001 wt% to 10 wt% to the weight % of the solid support, preferably in the range of 0.001 wt% to 5 wt% and more preferably in the range of 0.01 wt% to 2 wt%.
  • the complexing agent, supported or unsupported, is typically used in oxidation/functionalization reactions over the temperature range of -100°C to 300°C, preferably in the range of -50°C to 200°C, more preferably in the range of 0°C to 100°C.
  • Suitable solid support materials include, for example, inorganic oxides, silica, silicates, carbon, and polymeric materials such as polystyrenes, polyvinylchlorides, polyacrylates or polymethacrylates.
  • the oxidizing agent is a peroxide, particularly an organic peroxide, wherein at least a methyl group or higher alkyl or aryl is bound to one or both oxygen atoms of the peroxide.
  • the oxidizing agent is a sterically hindered peroxide, wherein the alkyl or aryl group associated with each oxygen atom is at least a secondary carbon, a tertiary carbon in another embodiment.
  • Non- limiting examples of useful sterically hindered peroxides include 2,5-bis(tert-butylperoxy)- 2,5-dimethylhexane, 2,5-dimethyl-2,5-bis-(t-butylperoxy)-hexyne-3,4-methyl-4-t- butylperoxy-2-pentanone, 3,6,6,9,9-pentamethyl-3-(ethylacetate)-l,2,4,5-textraoxy cyclononane, a,a'-bis-(tert-butylperoxy)diisopropyl benzene, and mixtures of these and any other secondary- or tertiary-hindered peroxides.
  • a preferred peroxide is 2,5-bis(tert- butylperoxy)-2,5-dimethyl-hexane, also known with the commercial name: LuperoxTM 101 or TrigonoxTM 101.
  • Another common peroxide used as an oxidizing agent is di-t-amyl peroxide, most commonly known with the commercial name DTAP.
  • Still other peroxidizing agents include peroxymonosulfates, such as potassium peroxymonosulfate known as OXONE .
  • the molar ratio of the oxidizing agents to the to-be-cleaved alkene will preferably be in the range from about 0.1 to about 10, more preferably from about 0.2 to about 8, and most preferably from about 0.3 to about 0.5 to 5.
  • the oxidizing agent contains hypervalent iodine.
  • Suitable examples include NaI0 4 , Dess-Martin Periodinane, Hydroxy(tosyloxy)iodobenzene, Iodosobenzene diacetate, Iodosobenzene bis(trifluoroacetate), Iodosylbenzene, 2-Iodoxybenzoic acid, or Iodobenzene dichloride.
  • the molar ratio of the oxidizing agent containing iodine to the to-be-cleaved alkene will preferably be in the range from about 0.1 to about 10, more preferably from about 0.2 to about 8, and most preferably from about 0.5 to about 5.
  • Iodonium salts are a class of molecules with the general structure of R2I X ⁇ , where R is alkyl-, aryl-, alkynyl-, alkenyl-, or fluoroalkyl groups, and X " is counter anion such as a halide, BF 4 " , PF 6 “ , AsF 6 “ , OTs “ , OTf and salts thereof.
  • each R is, independently, an alkyl, aryl, alkynyl, alkenyl, or fluoroalkenyl group, such as methyl, ethyl, propyl, butyl, phenyl, butenyl, propenyl and fluoropropenyl.
  • Hydrogenation can be carried out in the process of the present disclosure by any known hydrogenation catalysis system, including heterogeneous systems and soluble systems. Soluble systems are disclosed in U.S. Patent No. 4,284,835 at column 1, line 65 through column 9, line 16 as well as U.S. Patent No. 4,980,331 at column 3, line 40 through column 6, line 28.
  • substantially saturated as it refers to the polymer produced herein means that polymer includes on average fewer than 10 double bonds, or fewer than 5 double bonds, or fewer than 3 double bonds, or fewer than 1 double bond per 100 carbons in a hydrocarbon polymer chain. In a preferred embodiment of the invention, any polymer produced herein is substantially saturated.
  • the Rachapudy et al. article discloses a method of preparation of a homogeneous catalyst as well.
  • the catalyst can be formed by reaction between a metal alkyl and the organic salt of a transition metal.
  • the metal alkyls were n-butyl lithium (in cyclohexane) and triethyl aluminum (in hexane).
  • the metal salts were cobalt and nickel 2-ethyl hexanoates (in hydrocarbon solvents) and platinum and palladium acetyl-acetonates (solids). Hydrogenation was conducted in a 1 -liter heavy -wall glass reactor, fitted with a stainless steel flange top and magnetically stirred.
  • the Rachapudy et al. article also discloses a method of preparation of a heterogeneous catalyst.
  • a 1 -liter high-pressure reactor (Parr Instrument Co.) was used.
  • the catalysts were nickel on kieselguhr (Girdler Co.) and palladium on calcium carbonate (Strem Chemical Co.).
  • Approximately 5 grams of polybutadiene were dissolved in 500 milliliters of dry cyclohexane, the catalyst was added (approximately 0.01 moles metal/mole of double bonds), and the reactor was purged with hydrogen.
  • the reactor was then pressurized with hydrogen and the temperature was raised to the reaction temperature for 3 to 4 hours.
  • the reaction conditions were 700 psi 3 ⁇ 4 and 160°C.
  • the conditions were 500 psi H 2 and 70°C.
  • the hydrogen was removed and the solution filtered at 70°C. The polymer was precipitated with methanol and dried under vacuum.
  • the hydrogenation catalysts described herein can be used to hydrogenate hydrocarbons containing unsaturated carbon bonds.
  • the unsaturated carbon bonds which may be hydrogenated include olefinic and acetylenic unsaturated bonds.
  • the process is particularly suitable for the hydrogenation under mild conditions of hydrogenatable organic materials having carbon-to-carbon unsaturation, such as acyclic monoolefins and polyolefins, cyclic monoolefins and polyolefins, and mixtures thereof. These materials may be unsubstituted or substituted with additional non-reactive functional groups such as halogens, ether linkages or cyano groups.
  • carbon-to-carbon compounds useful herein are hydrocarbons of 2 to 30 carbon atoms, e.g., olefinic compounds selected from acyclic and cyclic mono-, di-, and triolefins.
  • the catalysts are also suitable for hydrogenating carbon-to-carbon unsaturation in polymeric materials, for example, in removing unsaturation from butadiene polymers and co-polymers such as styrene-butadiene- styrene.
  • the hydrogenation reaction herein is normally accomplished at a temperature from 40°C to 160°C and preferably from 60°C to 150°C. Different substrates being hydrogenated will require different optimum temperatures, which can be determined by experimentation.
  • the initial hydrogenation pressures may range up to 20.7 MPa partial pressure, at least part of which is present due to the hydrogen. Pressures from 0.0068 MPa to 51.7 MPa are suitable. Preferred pressures are up to 13.7 MPa, and most preferred pressures are from 0.68 to 6.8 MPa are employed.
  • the reactive conditions are determined by the particular choices of reactants and catalysts.
  • the process may be either batch or continuous. In a batch process, reaction times may vary widely, such as between 0.01 second to 10 hours. In a continuous process, reaction times may vary from 0.1 seconds to 120 minutes and preferably from 0.1 second to 10 minutes.
  • the ratio of catalyst to material being hydrogenated is generally not critical and may vary widely within the scope of the disclosure. Molar ratios of catalyst to material being hydrogenated between 1 : 1000 and 10: 1 are found to be satisfactory; higher and lower ratios, however, are possible. [0050] If desired, the hydrogenation process may be carried out in the presence of an inert diluent, for example, a paraffinic or cycloparaffinic hydrocarbon.
  • an inert diluent for example, a paraffinic or cycloparaffinic hydrocarbon.
  • any of the Group VIII metal compounds known to be useful in the preparation of catalysts for the hydrogenation of ethylenic unsaturation can be used separately or in combination to prepare the catalysts.
  • Suitable compounds include Group VIII metal carboxylates having the formula (RCOO) n M, wherein M is a Group VIII metal, R is a hydrocarbyl radical having from 1 to 50 carbon atoms, preferably from 5 to 30 carbon atoms, and n is a number equal to the valence of the metal M; alkoxides having the formula (RCO) n M, wherein M is again a Group VIII metal, R is a hydrocarbon radical having from 1 to 50 carbon atoms, preferably from 5 to 30 carbon atoms, and n is a number equal to the valence of the metal M; chelates of the metal prepared with beta-ketones, alpha- hydroxycarboxylic acids beta-hydroxycarboxylic acids, beta-hydroxycarbonyl compounds, and the like; salts of
  • the metal carboxylates useful in preparing the catalyst include Group VIII metal salts of hydrocarbon aliphatic acids, hydrocarbon cycloaliphatic acids, and hydrocarbon aromatic acids.
  • hydrocarbon aliphatic acids include hexanoic acid, ethylhexanoic acid, heptanoic acid, octanoic acid, nonanoic acid, decanoic acid, dodecanoic acid, myristic acid, palmitic acid, stearic acid, oleic acid, linoleic acid, and rhodinic acid.
  • hydrocarbon aromatic acids include benzoic acid and alkyl-substituted aromatic acids in which the alkyl substitution has from 1 to 20 carbon atoms.
  • cycloaliphatic acids include naphthenic acid, cyclohexylcarboxylic acid, and abietic-type resin acids.
  • Suitable chelating agents which may be combined with various Group VIII metal compounds thereby yielding a Group VIII metal chelate compound useful in the preparation of the catalyst include beta-ketones, alpha-hydroxycarboxylic acids, beta-hydroxy carboxylic acids, and beta-hydroxycarbonyl compounds.
  • beta-ketones that may be used include acetylacetone, 1,3-hexanedione, 3,5-nonadione, methylacetoacetate, and ethylacetoacetate.
  • alpha-hydroxycarboxylic acids examples include lactic acid, glycolic acid, alpha-hydroxyphenylacetic acid, alpha-hydroxy-alpha-phenylacetic acid, and alpha-hydroxycyclohexylacetic acid.
  • beta-hydroxycarboxylic acids examples include salicylic acid and alkyl-substituted salicylic acids.
  • beta- hydroxylcarbonyl compounds examples include salicylaldehyde and ⁇ -hydroxyacetophenone.
  • the metal alkoxides useful in preparing the catalysts include Group VIII metal alkoxides of hydrocarbon aliphatic alcohols, hydrocarbon cycloaliphatic alcohols, and hydrocarbon aromatic alcohols.
  • hydrocarbon aliphatic alcohols examples include hexanol, ethylhexanol, heptanol, octanol, nonanol, decanol, and dodecanol.
  • the Group VIII metal salts of sulfur-containing acids and partial esters thereof include Group VIII metal salts of sulfonic acid, sulfuric acid, sulphurous acid, and partial esters thereof.
  • aromatic sulfonic acids such as benzene sulfonic acid and p-toluene sulfonic acid are particularly useful.
  • any of the alkylalumoxane compounds known to be useful in the preparation of olefin polymerization catalysts may be used in the preparation of the hydrogenation catalyst.
  • Alkylalumoxane compounds useful in preparing the catalyst may, then, be cyclic or linear. Cyclic alkylalumoxanes may be represented by the general formula (R-Al-0) m while linear alkylalumoxanes may be represented by the general formula R(R-Al-0) n AlR2.
  • R will be an alkyl group having from 1 to 8 carbon atoms such as, for example, methyl, ethyl, propyl, butyl, and pentyl; m is an integer from 3 to 40; and n is an integer from 1 to 40. In a preferred embodiment, R will be methyl, m will be a number from 5 to 20, and n will be a number from 10 to 20.
  • alkylalumoxanes may be prepared by reacting an aluminum alkyl with water. Usually the resulting product will be a mixture of both linear and cyclic compounds.
  • the aluminum alkyl may first be dissolved in a suitable solvent such as toluene or an aliphatic hydrocarbon and the solution then contacted with a similar solvent containing relatively minor amounts of moisture.
  • a suitable solvent such as toluene or an aliphatic hydrocarbon
  • an aluminum alkyl may be contacted with a hydrated salt, such as hydrated copper sulfate or ferrous sulfate.
  • a hydrated ferrous sulfate is frequently used.
  • a dilute solution of aluminum alkyl in a suitable solvent such as toluene is contacted with hydrated ferrous sulfate.
  • any of the Group la, Ila, or Ilia metal alkyls or hydrides known to be useful in preparing hydrogenation catalysts in the prior art may be used to prepare the catalyst.
  • the Group la, Ila, or Ilia metal alkyls will be peralkyls with each alkyl group being the same or different containing from 1 to 8 carbon atoms and the hydrides will be perhydrides although alkylhydrides should be equally useful.
  • Aluminum, magnesium, and lithium alkyls and hydrides are particularly useful and these compounds are preferred for use in preparing the catalyst.
  • Aluminum trialkyls are most preferred.
  • the one or more alkylalumoxanes and the one or more Group la, Ila, or Ilia metal alkyls or hydrides may be combined and then contacted with the one or more Group VIII metal compounds or the one or more alkylalumoxanes and the one or more Group la, Ila, or Ilia metal alkyls or hydrides may be sequentially contacted with the one or more Group VIII metal compounds with the proviso that when sequential contacting is used, the one or more alkylalumoxanes will be first contacted with the one or more Group VIII metal compounds. Sequential contacting is preferred.
  • the two different reducing agents i.e., the alkylalumoxanes and the alkyls or hydrides
  • the Group VIII metal compound might react with the Group VIII metal compound in such a way as to yield different reaction products.
  • the Group la, Ila, and Ilia metal alkyls and hydrides are a stronger reducing agent than the alkylalumoxanes, and, as a result, if the Group VIII metal is allowed to be completely reduced with a Group la, Ila, or Ilia metal alkyl or hydride, the alkylalumoxanes might make little or no contribution.
  • the reaction product obtained with the alumoxane might be further reduced or otherwise altered by reaction with a Group la, Ila, or Ilia metal alkyl or hydride.
  • the one or more alkylalumoxanes will be combined with the one or more Group VIII metal compounds at a concentration sufficient to provide an aluminum to Group VIII metal atomic ratio within the range from 1.5: 1 to 20: 1 and the one or more Group la, Ila, or Ilia metal alkyls or hydrides will be combined with one or more Group VIII metal compounds at a concentration sufficient to provide a Group la, Ila, or Ilia metal to Group VIII metal atomic ratio within the range from 0.1 : 1 to 20: 1.
  • Contact between the one or more Group VIII compounds and the one or more alkylalumoxanes and the one or more alkyls or hydrides will be accomplished at a temperature within the range from 20°C and 100°C. Contact will typically be continued for a period of time within the range from 1 to 120 minutes. When sequential contacting is used, each of the two contacting steps will be continued for a period of time within this same range.
  • the hydrogenation catalyst will be prepared by combining the one or more Group VIII metal compounds with the one or more alkylalumoxanes and the one or more Group la, Ila, or Ilia metal alkyls or hydrides in a suitable solvent.
  • the solvent used for preparing the catalyst may be anyone of those solvents known in the prior art to be useful as solvents for unsaturated hydrocarbon polymers.
  • Suitable solvents include aliphatic hydrocarbons such as hexane, heptane, and octane; cycloaliphatic hydrocarbons such as cyclopentane and cyclohexane; alkyl-substituted cycloaliphatic hydrocarbons such as methylcyclopentane, methylcyclohexane, and methylcyclooctane; aromatic hydrocarbons such as benzene; hydroaromatic hydrocarbons such as decalin and tetralin; alkyl-substituted aromatic hydrocarbons such as toluene and xylene; halogenated aromatic hydrocarbons such as chlorobenzene; and linear and cyclic ethers such as the various dialkyl ethers, polyethers, particularly diethers, and tetrahydrofuran.
  • Suitable hydrogenation catalysts will usually be prepared by combining the catalyst components in a separate vessel prior to feeding the same to the hydrogenation reactor.
  • Polymers having internal unsaturations are those olefin polymers that have at least one carbon-carbon double bond in the backbone of a polymer chain.
  • Back bone carbon- carbon double bonds are distinguished from pendant unsaturations by either l H NMR or 13 C NMR.
  • protons at internal unsaturations typically are at 5.4 ppm while protons at pendant unsaturation sites typically are at 5.0 ppm.
  • unsaturated polydiene is useful as the polymers having internal unsaturations.
  • polymers of conjugated dienes are particularly useful.
  • Preferred examples include polybutadiene, polyisobutylene, butyl rubber, polyisoprene, nitrile rubber, block copolymers having blocks of polyaromatices (such as polystyrene) and blocks of poly dienes (such as polyisoprene, polybutadiene, SIS, SBS, etc.).
  • the polymer having internal unsaturations is polybutadiene, polyisoprene, and or nitrile rubber having a M w between 80,000 and 250,000 g/mol.
  • Polymer or copolymer properties can include iodine values from 10 to 470g 12/lOOg polymer.
  • the polymer having internal unsaturations includes a styrenic block copolymer comprised of triblock segments comprised of styrene-derived units and at least one other unit selected from the group consisting of butadiene-derived units, isoprene- derived units, isobutylene-derived units and wherein the styrenic block copolymer is comprised of less than 20 wt% of diblock segments.
  • styrenic block copolymer means a block copolymer of styrene and or alpha-methyl-styrene and an olefin such as an alpha olefin (ethylene, propylene, butene) or an alkadiene (isobutylene, isoprene, butadiene) and hydrogenated or chemically modified versions of the block copolymer.
  • the block copolymers may be in diblock, triblock, linear (including tapered) or radial (including tapered) block form.
  • the SBC is an elastomeric styrenic block copolymer having an elongation at break of at least 500% and a tensile strength of at least 6 MPa measured according to ASTM D412.
  • the SBC has a wt% styrene of 10 to 60 wt%, preferably 15 to 50 wt%, preferably at 20 to 40 wt%, based upon the weight of the SBC.
  • aromatic segments are present in the SBC at 10 to 85 wt%, preferably 15 to 50 wt%, preferably at 20 to 50 wt%, based upon the weight of the SBC.
  • the SBC comprises at least one block of styrene and at least one block of units selected from the group consisting of ethylene, butadiene, isoprene, and isobutylene, wherein the SBC comprises of from 10 to 85 wt% styrene, based upon the weight of the SBC.
  • Particularly preferred SBC's can include linear block copolymers, exemplified by the structural designations as A-B diblock copolymers, A-B-A triblock copolymers, A-B-A-B tetrablock copolymers, A-B-A-B-A pentablock copolymers, and so on.
  • Such SBC's generally comprise a thermoplastic A block portion and an elastomeric B block portion.
  • the hard A block portion generally comprises a polyvinylarene derived from monomers such as styrene, a-methyl styrene, other styrene derivatives, or mixtures thereof.
  • the hard A block portion can be polystyrene, having a number-average molecular weight between from about 1,000 to about 200,000, preferably from about 2,000 to about 100,000, more preferably from about 5,000 to about 60,000.
  • the hard A block portion comprises from about 5% to about 80%, preferably from about 10% to about 70%, more preferably from about 10% to about 50% of the total weight of the SBC.
  • the material forming the B block can have sufficiently low Tg at the use temperature of the polymer such that crystalline or glassy domains are not formed at these working temperatures.
  • the B block may thus be regarded as a soft block.
  • the soft B block portion is typically an olefinic polymer derived from conjugated aliphatic diene monomers of from about 4 to about 6 carbon atoms, linear alkene monomers of from about 2 to about 6 carbon atoms, or the like, including mixtures.
  • Representative diene monomers include butadiene, isoprene, and the like.
  • Representative alkene monomers include ethylene, propylene, butylene, and the like.
  • the number average molecular weight of the soft B block is typically from about 1,000 to about 300,000, preferably from about 10,000 to about 200,000, and more preferably from about 20,000 to about 100,000.
  • the soft B block portion comprises from about 20% to about 90%, preferably from about 30% to about 80%, more preferably from about 40% to about 80% of the total weight of the SBC.
  • the soft B blocks comprise at least about 50% by weight of the SBC.
  • the SBC's are triblock copolymers having an elastomeric midblock B and thermoplastic endblocks A and A', wherein A and A' may be derived from the same or different vinylarene monomers.
  • the SBC's may also be radial, having three or more arms, each arm being a B-A, B-A-B-A, or the like type copolymer and the B blocks being at or near the center portion of the radial polymer.
  • the SBC's may have four, five, or six arms.
  • the unsaturation in olefinic double bonds may be selectively hydrogenated to reduce sensitivity to oxidative degradation and may have beneficial effects on the elastomeric properties.
  • a polyisoprene block can be selectively reduced to form an ethylene-propylene block.
  • the vinylarene block typically comprises at least about 10% by weight of the SBC.
  • Exemplary SBC's for use herein are commercially available from Dexco Polymers LP (Plaquemine, La.) under the tradename VECTORTM and from Kraton Polymers (Houston, Tex.) under the tradename KRATONTM, particularly Kraton 1641, 6944, 1650, 1657, 1651. SBC's can also be obtained from Total Petrochemicals under the tradename FINAPRENETM and from ASAHI in Japan, from Dynasol under the tradename Calprene, JSR under the tradename Dynaron, Polimeri under the name Europrene and TSRC under the name TAIPOL and Kuraray America, Inc. under the tradename SEPTONTM.
  • the polymer having internal unsaturations can be butyl rubber.
  • Butyl rubber is a copolymer of a C 4 to C7 isoolefin monomer component such as isobutylene with a multiolefin, or conjugated diene, monomer component, such as isoprene.
  • the isoolefin is present in the range from 70 to 99.5 weight percent (preferably 85 to 99.5 weight percent), based upon the weight of the butyl rubber and the conjugated diene component is present at from 30 to 0.5 weight percent (preferably from 15 to 0.5 weight percent, preferably from 8 to 0.5 weight percent) based upon the weight of the butyl rubber.
  • the isoolefin is a C 4 to C7 compound such as isobutylene, isobutene 2-methyl-l-butene, 3- methyl- 1-butene, 2-methyl-2-butene, and 4-methyl- 1 -pentene.
  • the multiolefin is a C 4 to Ci 4 conjugated diene such as isoprene, butadiene, 2,3 -dimethyl- 1,3 -butadiene, myrcene, 6,6- dimethyl-fulvene, cyclopentadiene, hexadiene and piperylene.
  • the polymer having internal unsaturations is one or more of polyisoprene rubber, polybutadiene rubber, styrene-butadiene rubber, butadiene-acrylonitrile rubber.
  • the polymer having internal unsaturations is one or more of: natural rubber (polyisoprene), butyl rubber, halobutyl rubber, halogenated rubber copolymer of p-alkystyrene and at least one C 4 -C7 isomonoolefin, a copolymer of isobutylene and divinyl-benzene, homopolymers of a conjugated diene (preferably a C 4 -Cs conjugated diene), copolymers of at least one conjugated diene and a comonomer (preferably where the copolymer has at least 50 wt% repeat units from at least one C 4 -Cs conjugated diene and/or the comonomer is a polar monomer, a C 8 -C 12 vinyl aromatic monomer, an acrylonitrile monomer, a C3-C8 alkyl substituted acrylonitrile monomer, an unsaturation of a conjugated diene and a
  • the polymer having internal unsaturations has an M n of 1000 g/mol or more, preferably 5,000 g/mol or more, preferably 10,000 g/mol or more, preferably 55,000 g/mol or more, preferably 75,000 g/mol or more, preferably 100,000 g/mol or more and preferably 1,000,000 g/mol or less, preferably 500,000 g/mol or less.
  • Polyolefins such as polyethylene that have been subjected to controlled rheology (such as thermal or peroxide degradation) can also be used with or in place of polymers with internal unsaturations.
  • polymers having vinyl or vinylidene unsaturations can also be used with or in place of polymers with internal unsaturations.
  • polymers having allyl chain ends are used with or in place of polymers with internal unsaturations.
  • Polymers having allyl chain ends include vinyl terminated macromonomers (also referred to as “vinyl terminated oligomers” or “macromers”) and vinyl terminated polyolefins which comprise vinyl terminated macromonomers.
  • Macromonomers having allyl chain ends are referred to as "vinyl terminated macromonomers”.
  • the vinyl terminated polyolefm comprises macromonomers having at least 5% (at least 10%, at least 15%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%; at least 80%, at least 90%, or at least 95%) allyl chain ends (relative to total unsaturation).
  • the vinyl terminated macromonomers have a M n in the range of from about 300 g/mol to about 30,000 g/mol.
  • the vinyl terminated macromonomers are a recycle stream from another process, such as a polyalphaolefin process, and may comprise a mixture of different macromonomers.
  • the vinyl terminated macromonomer includes, one or more of:
  • a vinyl terminated polymer having an M n of at least 200 g/mol (measured by l R NMR) comprising of one or more C 4 to C 4 Q higher olefin derived units, where the higher olefin polymer comprises substantially no propylene derived units; and wherein the higher olefin polymer has at least 5% allyl chain ends;
  • a copolymer having an M n of 200 g/mol or more comprising (a) from about 20 mol% to about 99.9 mol% of at least one C5 to C 4 Q higher olefin, and (b) from about 0.1 mol% to about 80 mol% of propylene, wherein the higher olefin copolymer has at least 40% allyl chain ends;
  • NMR NMR
  • a propylene oligomer comprising more than 90 mol% propylene and less than 10 mol% ethylene wherein the oligomer has: at least 93% allyl chain ends, a number average molecular weight (M n ) of about 500 g/mol to about 20,000 g/mol, an isobutyl chain end to allylic vinyl group ratio of 0.8: 1 to 1.35: 1.0, and less than 100 ppm aluminum;
  • a propylene oligomer comprising: at least 50 mol% propylene and from 10 mol% to 50 mol% ethylene, wherein the oligomer has: at least 90% allyl chain ends, an M n of about 150 g/mol to about 10,000 g/mol, and an isobutyl chain end to allylic vinyl group ratio of 0.8: 1 to 1.2: 1.0, wherein monomers having four or more carbon atoms are present at from 0 mol% to 3 mol%;
  • a propylene oligomer comprising: at least 50 mol% propylene, from 0.1 mol% to 45 mol% ethylene, and from 0.1 mol% to 5 mol% C 4 to olefin, wherein the oligomer has: at least 90% allyl chain ends, an M n of about 150 g/mol to about 10,000 g/mol, and an isobutyl chain end to allylic vinyl group ratio of 0.8: 1 to 1.35: 1.0;
  • a propylene oligomer comprising: at least 50 mol% propylene, from 0.1 mol% to 45 mol% ethylene, and from 0.1 mol% to 5 mol% diene (preferably such as C 4 to alpha-omega dienes (such as butadiene, hexadiene, octadiene), norbornene, ethylidene norbornene, vinylnorbornene, norbornadiene, and dicyclopentadiene), wherein the oligomer has: at least 90% allyl chain ends, an M n of about 150 g/mol to about 10,000 g/mol, and an isobutyl chain end to allylic vinyl group ratio of 0.7: 1 to 1.35: 1.0;
  • diene preferably such as C 4 to alpha-omega dienes (such as butadiene, hexadiene, octadiene), norbornene, ethylidene norbornene, vinyl
  • (x) a co-oligomer having an M n ( l ⁇ i NMR) of 7,500 to 60,000 g/mol comprising one or more alpha olefin derived units comprising ethylene and/or propylene, having 50% or greater allyl chain ends, relative to total number of unsaturated chain ends, and a g'vis of 0.90 or less (g'vis is determined using GPC-DRI, as described below);
  • a branched polyolefin having an M n ( ⁇ H NMR) of less than 7,500 g/mol comprising one or more alpha olefin derived units comprising ethylene and/or propylene, having: a ratio of percentage of saturated chain ends to percentage of allyl chain ends of 1.2 to 2.0 and 50% or greater allyl chain ends, relative to total unsaturated chain ends.
  • Any of the vinyl terminated macromonomers described herein may be homopolymers, copolymers, terpolymers, and so on.
  • the vinyl terminated macromonomers may have a Tg of less than 0°C or less (as determined by differential scanning calorimetry as described below), preferably -10°C or less, more preferably -20°C or less, more preferably -30°C or less, more preferably -50°C or less.
  • the vinyl terminated macromonomers described herein may have a melting point (DSC first melt, as described below) of from 60°C to 130°C, alternately 50°C to 100°C.
  • the vinyl terminated macromonomers described herein have no detectable melting point by DSC following storage at ambient temperature (23°C) for at least 48 hours.
  • the vinyl terminated macromonomers may be a liquid at 25°C.
  • the vinyl terminated macromonomers may have an isobutyl chain end to allylic vinyl group ratio of 0.7: 1 to 1.35: 1.0, preferably 0.8: 1 to 1.35: 1.0, and more preferably 0.8: 1 to 1.2: 1.0.
  • the vinyl terminated macromonomers may have less than 3 wt% of functional groups selected from hydroxide, aryls and substituted aryls, halogens, alkoxys, carboxylates, esters, acrylates, oxygen, nitrogen, and carboxyl, preferably less than 2 wt%, more preferably less than 1 wt%, more preferably less than 0.5 wt%, more preferably less than 0.1 wt%, more preferably 0 wt%, based upon the weight of the oligomer.
  • functional groups selected from hydroxide, aryls and substituted aryls, halogens, alkoxys, carboxylates, esters, acrylates, oxygen, nitrogen, and carboxyl, preferably less than 2 wt%, more preferably less than 1 wt%, more preferably less than 0.5 wt%, more preferably less than 0.1 wt%, more preferably 0 wt%, based upon the weight of the oligo
  • Vinyl terminated macromonomers generally have a saturated chain end (or terminus) and/or an unsaturated chain end or terminus.
  • the unsaturated chain end of the vinyl terminated macromonomer comprises an "allyl chain end” or a "3-alkyl” chain end.
  • An allyl chain end is represented by CH ⁇ CH-CH ⁇ ., as shown in the formula: where M represents the polymer chain.
  • “Allylic vinyl group,” “allyl chain end,” “vinyl chain end,” “vinyl termination,” “allylic vinyl group,” and “vinyl terminated” are used interchangeably in the following description.
  • the number of allyl chain ends, vinylidene chain ends, vinylene chain ends, and other unsaturated chain ends is determined using l R NMR at 120°C using deuterated tetrachloroethane as the solvent on an at least 250 MHz NMR spectrometer, and in selected cases, confirmed by 13 C NMR.
  • a 3-alkyl chain end (where the alkyl is a to C38 alkyl), also referred to as a "3- alkyl vinyl end group” or a “3-alkyl vinyl termination,” is represented by the formula:
  • 3-alkyl vinyl end group where " ⁇ " represents the polyolefin chain and R b is a Q to C38 alkyl group, or a Q to C20 alkyl group, such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, and the like.
  • the amount of 3-alkyl chain ends is determined using 13 C NMR as set out below.
  • 13 C NMR data is collected at 120°C at a frequency of at least 100 MHz, using a BRUKER 400 MHz NMR spectrometer.
  • a 90 degree pulse, an acquisition time adjusted to give a digital resolution between 0.1 and 0.12 Hz, at least a 10 second pulse acquisition delay time with continuous broadband proton decoupling using swept square wave modulation without gating is employed during the entire acquisition period.
  • the spectra is acquired with time averaging to provide a signal to noise level adequate to measure the signals of interest.
  • Samples are dissolved in tetrachloroethane-d2 at concentrations between 10 wt% to 15 wt% prior to being inserted into the spectrometer magnet.
  • the "allyl chain end to vinylidene chain end ratio” is defined to be the ratio of the percentage of allyl chain ends to the percentage of vinylidene chain ends.
  • the “allyl chain end to vinylene chain end ratio” is defined to be the ratio of the percentage of allyl chain ends to the percentage of vinylene chain ends.
  • Vinyl terminated macromonomers typically also have a saturated chain end. In polymerizations where propylene is present, the polymer chain may initiate growth in a propylene monomer, thereby generating an isobutyl chain end.
  • An “isobutyl chain end” is defined to be an end or terminus of a polymer, represented as shown in the formula below:
  • isobutyl chain end where M represents the polymer chain. Isobutyl chain ends are determined according to the procedure set out in WO 2009/155471.
  • the "isobutyl chain end to allylic vinyl group ratio" is defined to be the ratio of the percentage of isobutyl chain ends to the percentage of allyl chain ends.
  • the saturated chain end may be a C 4 or greater (or "higher olefin”) chain end, as shown in the formula below:
  • M represents the polymer chain and n is an integer selected from 4 to 40. This is especially true when there is substantially no ethylene or propylene in the polymerization.
  • the polymer chain may initiate growth in an ethylene monomer, thereby generating a saturated chain end which is an ethyl chain end.
  • M n ( ⁇ ⁇ NMR) is determined according to the following NMR method.
  • Tm, Hf, and Tg are measured using Differential Scanning Calorimetry (DSC) using commercially available equipment such as a TA Instruments Model Q100.
  • DSC Differential Scanning Calorimetry
  • 6 to 10 mg of the sample, that has been stored at room temperature for at least 48 hours, is sealed in an aluminum pan and loaded into the instrument at room temperature.
  • the sample is equilibrated at 25°C, then it is cooled at a cooling rate of 10°C/min to -80°C.
  • the sample is held at -80°C for 5 min and then heated at a heating rate of 10°C/min to 25°C.
  • the glass transition temperature is measured from the heating cycle.
  • the sample is equilibrated at 25°C for 5 minutes, then heated at a heating rate of 10°C/min to 200°C, followed by an equilibration at 200°C for 5 minutes, and cooled at 10°C/min to -80°C.
  • the endothermic melting transition if present, is analyzed for onset of transition and peak temperature.
  • the melting temperatures reported are the peak melting temperatures from the first heat unless otherwise specified.
  • the melting point (or melting temperature) is defined to be the peak melting temperature associated with the largest endothermic calorimetric response in that range of temperatures from the DSC melting trace.
  • Areas under the DSC curve are used to determine the heat of transition (heat of fusion, Hf, upon melting or heat of crystallization, He, upon crystallization, if the Hf value from the melting is different from the He value obtained for the heat of crystallization, then the value from the melting (Tm) shall be used), which can be used to calculate the degree of crystallinity (also called the percent crystallinity).
  • the percent crystallinity (X%) is calculated using the formula: [area under the curve (in J/g) / H° (in J/g)] * 100, where H° is the heat of fusion for the homopolymer of the major monomer component.
  • H° equilibrium heat of fusion
  • a value of 290 J/g is used as the equilibrium heat of fusion (H°) for 100% crystalline polyethylene
  • a value of 140 J/g is used as the equilibrium heat of fusion (H°) for 100% crystalline polybutene
  • a value of 207 J/g (H°) is used as the heat of fusion for a 100% crystalline polypropylene.
  • the vinyl terminated macromonomer has an M n of at least 200 g/mol, (e.g., 200 g/mol to 100,000 g/mol, e.g., 200 g/mol to 75,000 g/mol, e.g., 200 g/mol to 60,000 g/mol, e.g., 300 g/mol to 60,000 g/mol, or e.g., 750 g/mol to 30,000 g/mol) (measured by l R NMR) and comprise one or more (e.g., two or more, three or more, four or more, and the like) C 4 to C 4 Q (e.g., C 4 to C30, C 4 to C20, or C 4 to C ⁇ , e.g., butene, pentene, hexene, heptene, octene, nonene, decene, undecene, dodecene, norbornene,
  • M n of at least 200 g
  • the vinyl terminated macromonomers may also comprise ethylene derived units, e.g., at least 5 mol% ethylene (e.g., at least 15 mol% ethylene, e.g., at least 25 mol% ethylene, e.g., at least 35 mol% ethylene, e.g., at least 45 mol% ethylene, e.g., at least 60 mol% ethylene, e.g., at least 75 mol% ethylene, or e.g., at least 90 mol% ethylene).
  • ethylene derived units e.g., at least 5 mol% ethylene (e.g., at least 15 mol% ethylene, e.g., at least 25 mol% ethylene, e.g., at least 35 mol% ethylene, e.g., at least 45 mol% ethylene, e.g., at least 60 mol% ethylene, e.g., at least 75 mol% ethylene, or e.g.
  • the vinyl terminated macromonomers may have an M n (measured by l R NMR) of greater than 200 g/mol (e.g., 300 g/mol to 60,000 g/mol, 400 g/mol to 50,000 g/mol, 500 g/mol to 35,000 g/mol, 300 g/mol to 15,000 g/mol, 400 g/mol to 12,000 g/mol, or 750 g/mol to 10,000 g/mol), and comprise:
  • the vinyl terminated macromonomer has an M n of 300 g/mol or more (measured by l R NMR, e.g., 300 g/mol to 60,000 g/mol, 400 g/mol to 50,000 g/mol, 500 g/mol to 35,000 g/mol, 300 g/mol to 15,000 g/mol, 400 g/mol to 12,000 g/mol, or 750 g/mol to 10,000 g/mol), and comprises:
  • the vinyl terminated macromonomer has at least 40% allyl chain ends (e.g., at least 50% allyl chain ends, at least 60% allyl chain ends, at least 70% allyl chain ends, at least 80% allyl chain ends, at least 90% allyl chain ends, or at least 95% allyl chain ends) relative to total unsaturation; and in some embodiments, an isobutyl chain end to allyl chain end ratio of less than 0.70: 1, less than 0.65: 1, less than 0.60: 1, less than 0.50: 1, or less than 0.25: 1 ; and in further embodiments, an allyl chain end to vinylidene group ratio of more than 2: 1, more than 2.5: 1, more than 3 : 1, more than 5: 1, or more than 10: 1.
  • allyl chain ends e.g., at least 50% allyl chain ends, at least 60% allyl chain ends, at least 70% allyl chain ends, at least 80% allyl chain ends, at least 90% allyl chain ends, or at least 95%
  • the vinyl terminated macromonomer is a propylene co-oligomer having an M n of 300 g/mol to 30,000 g/mol as measured by NMR (e.g., 400 g/mol to 20,000 g/mol, e.g., 500 g/mol to 15,000 g/mol, e.g., 600 g/mol to 12,000 g/mol, e.g., 800 g/mol to 10,000 g/mol, e.g., 900 g/mol to 8,000 g/mol, e.g., 900 g/mol to 7,000 g/mol), comprising 10 mol% to 90 mol% propylene (e.g., 15 mol% to 85 mol%, e.g., 20 mol% to 80 mol%, e.g., 30 mol% to 75 mol%, e.g., 50 mol% to 90 mol%) and 10 mol% to 90 mol.
  • M n 300 g/mol
  • the vinyl terminated macromonomer is a propylene oligomer, comprising more than 90 mol% propylene (e.g., 95 mol% to 99 mol%, e.g., 98 mol% to 9 mol%) and less than 10 mol% ethylene (e.g., 1 mol% to 4 mol%, e.g., 1 mol% to 2 mol%), wherein the oligomer has: at least 93% allyl chain ends (e.g., at least 95%, e.g., at least 97%, e.g., at least 98%); a number average molecular weight (M n ) of about 400 g/mol to about 30,000 g/mol, as measured by l K NMR (e.g., 500 g/mol to 20,000 g/mol, e.g., 600 g/mol to 15,000 g/mol, e.g., 700 g/mol to 10,000
  • the vinyl terminated macromonomer is a propylene oligomer, comprising: at least 50 mol% (e.g., 60 mol% to 90 mol%, e.g., 70 mol% to 90 mol%) propylene and from 10 mol% to 50 mol% (e.g., 10 mol% to 40 mol%, e.g., 10 mol% to 30 mol%) ethylene, wherein the oligomer has: at least 90% allyl chain ends (e.g., at least 91%, e.g., at least 93%, e.g., at least 95%, e.g., at least 98%); an M n of about 150 g/mol to about 20,000 g/mol, as measured by l K NMR (e.g., 200 g/mol to 15,000 g/mol, e.g., 250 g/mol to 15,000 g/mol, e.g., 300 g
  • the vinyl terminated macromonomer is a propylene oligomer, comprising: at least 50 mol% (e.g., at least 60 mol%, e.g., 70 mol% to 99.5 mol%, e.g., 80 mol% to 99 mol%, e.g., 90 mol% to 98.5 mol%) propylene, from 0.1 mol% to 45 mol% (e.g., at least 35 mol%, e.g., 0.5 mol% to 30 mol%, e.g., 1 mol% to 20 mol%, e.g., 1.5 mol% to 10 mol%) ethylene, and from 0.1 mol% to 5 mol% (e.g., 0.5 mol% to 3 mol%, e.g., 0.5 mol% to 1 mol%) C 4 to (3 ⁇ 4 olefin (such as butene, hexene, or octen
  • the vinyl terminated macromonomer is a propylene oligomer, comprising: at least 50 mol% (e.g., at least 60 mol%, e.g., 70 mol% to 99.5 mol%, e.g., 80 mol% to 99 mol%, e.g., 90 mol% to 98.5 mol%) propylene, from 0.1 mol% to 45 mol% (e.g., at least 35 mol%, e.g., 0.5 mol% to 30 mol%, e.g., 1 mol% to 20 mol%, e.g., 1.5 mol% to 10 mol%) ethylene, and from 0.1 mol% to 5 mol% (e.g., 0.5 mol% to 3 mol%, e.g., 0.5 mol% to 1 mol%) diene (such as C 4 to alpha-omega dienes (such as butadiene, hexa
  • the vinyl terminated macromonomer is a propylene homo-oligomer, comprising propylene and less than 0.5 wt% comonomer, e.g., 0 wt% comonomer, wherein the oligomer has:
  • At least 93% allyl chain ends e.g., at least 95%, e.g., at least 96%, e.g., at least 97%, e.g., at least 98%, e.g., at least 99%;
  • M n a number average molecular weight (M n ) of about 500 g/mol to about 20,000 g/mol, as measured by l R NMR (e.g., 500 g/mol to 15,000 g/mol, e.g., 700 g/mol to 10,000 g/mol, e.g., 800 g/mol to 8,000 g/mol, e.g., 900 g/mol to 7,000 g/mol, e.g., 1,000 g/mol to 6,000 g/mol, e.g., 1,000 g/mol to 5,000 g/mol);
  • the vinyl terminated macromonomer is a branched polyolefin having an M n (measured by l R NMR) of 7,500 to 60,000 g/mol, comprising one or more alpha olefins (preferably propylene and/or ethylene, preferably propylene) and, optionally, a C 4 to C 4 Q alpha olefin (preferably a C 4 to C20 alpha olefin, preferably a C 4 to alpha olefin, preferably butene, pentene, hexene, heptene, octene, nonene, decene, cyclopentene, cycloheptene, cyclooctene, cyclooctadiene, and isomers thereof), and having:
  • a g'vis of 0.90 or less (preferably 0.85 or less, preferably 0.80 or less); and/or a ratio of percentage of saturated chain ends (preferably isobutyl chain ends) to percentage of allyl chain ends of 1.2 to 2.0 (preferably 1.6 to 1.8), wherein the percentage of saturated chain ends is determined using 13 C NMR as described in WO 2009/155471 at paragraphs [0095] and [0096] except that the spectra are referenced to the chemical shift of the solvent, tetrachloroethane-d2, and/or a ratio of NMR) of 0.95 or less (preferably 0.90 or less, preferably 0.85 or less, preferably 0.80 or less);
  • Tm peak melting point
  • Hf heat of fusion
  • an allyl chain end to vinylene chain end ratio of greater than 1 : 1 (preferably greater than 2: 1, greater than 5: 1, or greater than 10: 1).
  • Such macromonomers and methods to make them are further described in USSN 13/411,929, filed on March 5, 2012, which is incorporated in its entirety herein.
  • the vinyl terminated macromonomer is a branched polyolefin having an M n (measured by GPC) of greater than 60,000 g/mol, comprising one or more alpha olefins (preferably propylene and/or ethylene, preferably propylene) and optionally, a C 4 to C 4 Q alpha olefin (preferably a C 4 to C20 alpha olefin, preferably a C 4 to alpha olefin, preferably butene, pentene, hexene, heptene, octene, nonene, decene, cyclopentene, cycloheptene, cyclooctene, cyclooctadiene, and isomers thereof) and having:
  • Tm optionally, a Tm of greater than 60°C (preferably greater than 100°C, preferably from 60°C to 180°C, preferably from 80°C to 175°C);
  • an Hf of greater than 7 J/g preferably greater than 15 J/g, greater than 30 J/g, greater than 50 J/g, greater than 60 J/g, or greater than 80 J/g.
  • the vinyl terminated macromonomer is a branched polyolefin having an M n (measured by NMR) of less than 7,500 g/mol (preferably from 100 to 7,500 g/mol), comprising one or more alpha olefins (preferably propylene and/or ethylene, preferably propylene) and, optionally, a C 4 to C 4 Q alpha olefin (preferably a C 4 to C20 alpha olefin, preferably a C 4 to (3 ⁇ 4 alpha olefin, preferably butene, pentene, hexene, heptene, octene, nonene, decene, cyclopentene, cycloheptene, cyclooctene, cyclooctadiene, and isomers thereof) and having:
  • Tm optionally, a Tm of greater than 60°C (preferably greater than 100°C, preferably from 60 to 180°C, preferably from 80 to 175°C);
  • an Hf of greater than 7 J/g preferably greater than 15 J/g, greater than 30 J/g, greater than 50 J/g, greater than 60 J/g, or greater than 80 J/g;
  • an allyl chain end to vinylene chain end ratio of greater than 1 : 1 (preferably greater than 2: 1, greater than 5: 1, or greater than 10: 1).
  • Such macromonomers and methods to make them are further described in USSN 13/41 1,929, filed on March 5, 2012, which is incorporated in its entirety herein.
  • the vinyl terminated macromonomer may be a vinyl terminated ethylene macromonomer.
  • a phenoxyimine-based catalyst a Mitsui FI catalyst
  • a pyrroleimine-based catalyst a Mitsui PI catalyst
  • These catalysts comprise (a) a transition metal (preferably Ti) compound having phenoxyimine or pyrroleimine as a ligand, and (b) one or more kind(s) of compound selected from (b-1) an organic metal compound, (b- 2) an organic aluminumoxy compound, and (b-3) a compound that reacts with the transition metal compound (a) to form an ion pair, as described in JP-A-2001-72706, JP-A-2002- 332312, JP-A-2003-313247, JP-A-2004- 107486, and JP-A-2004- 107563.
  • the transition metal contained in the transition metal compound the transition metal of Groups 3 to 11 in the periodic table can be used.
  • Preferred catalysts to prepare the vinyl terminated ethylene macromonomer include those described in US 7,795,347, specifically at column 16, line 56 et seq. in Formula (XI).
  • the vinyl terminated macromonomer may be a vinyl terminated isotactic polypropylene or a vinyl terminated polyethylene as disclosed in US 6,444,773, US 6,555,635, US 6, 147, 180, US 6,660,809, US 6,750,307, US 6,774, 191, EP 0 958 309, and US 6, 169,154, which are incorporated by reference herein.
  • any vinyl terminated macromonomer described herein can be fractionated or distilled by any means know in the art and one or more of the fractions may be used in the invention described herein.
  • Preferred fractions typically have a narrow M w /M n , such as less than 1.5, preferably 1.4 or less, preferably 1.3 or less, preferably 1.2 or less.
  • the M w /M n is from 1 to 1.4, preferably 1.05 to 1.3, preferably 1.1 to 1.2.
  • the functionalized polyolefin has an acid number from 10 to 100, for example, from 20 to 60. Acid number is determined according to ASTM D974.
  • the reaction benefits from the use of two liquid solvent phases which are at least partially miscible, and a phase transfer catalyst which is soluble in the same liquid phase as the oxidizing agent and forms a complex therewith which is soluble in the other liquid phase.
  • the complex transfers into the other liquid phase where the oxidizing agent oxidizes sites of unsaturation and creates desired pendant functionality, e.g., aldehyde, ketone, or carboxylic acid groups.
  • phase transfer catalyst useful in the present invention preferably comprises a salt compound, more preferably a Group 15 salt compound, and most preferably a quaternary ammonium salt compound.
  • phase transfer catalysts useful in two phase reactions include (but are not limited to): tetrabutyl ammonium bromide, tetrabutyl ammonium bisulfate, tetrabutyl ammonium hydroxide, benzyl triethyl ammonium chloride, tetrabutyl phosphonium bromide, etc.
  • a particularly preferred phase transfer catalyst is tetrabutyl ammonium bromide.
  • the molar ratio of the phase transfer catalyst to oxidant will preferably be in the range from about 0.1 to about 1, more preferably from about 0.2 to about 0.8, and most preferably from about 0.3 to about 0.5.
  • Reaction temperatures will range from about 20°C to about 150°C, preferably from about 50°C to about 100°C, preferably from about 75°C to about 85°C. The temperatures are for non-flux conditions.
  • the functionalized polymers prepared herein can be used in oil additives, as anti- fogging or wetting additives, adhesion promoters and many other applications. Preferred uses include additives for lubricants and or fuels, as plasticizers, surfactants for soaps, detergents, fabric softeners, antistatics, etc.
  • the functionalized polymer can in turn be derivatized with a derivatizing compound.
  • the derivatizing compound can react with the functional groups of the functionalized polymer by means such as nucleophilic substitution, Mannich Base condensation, and the like.
  • the derivatizing compound can be polar and/or contain reactive derivative groups.
  • Preferred derivatizing compounds are selected from hydroxy containing compounds, amines, metal salts, anhydride containing compounds and acetyl halide containing compounds.
  • the derivatizing compounds can comprise at least one nucleophilic group and preferably at least two nucleophilic groups.
  • a typical derivatized polymer is made by contacting a functionalized polymer, i.e., substituted with a carboxylic acid or ketone, with a nucleophilic reagent, e.g., amine, alcohol, including polyols, amino alcohols, reactive metal compounds and the like. (For more information please see US 6,022,929 column 33, line 27 to column 74, line 63.) Alternately, a derivatized polymer may be made by contacting a functionalized polymer, substituted with a carboxylic acid or ketone, with a nucleophilic reagent, e.g., amine, to make a quaternary ammonium compound or amine oxide.
  • a nucleophilic reagent e.g., amine, to make a quaternary ammonium compound or amine oxide.
  • the functionalized polymers and/or derivatized polymers have uses as lubricating additives which can act as dispersants, viscosity index improvers, or multifunctional viscosity index improvers. Additionally, they may be used as disinfectants (functionalized amines) and or wetting agents.
  • Functionalized polymers and/or derivatized polymers having uses as dispersants typically have M n 's (g/mol) of less than 20,000, preferably less than 10,000 and most preferably less than 8,000 and typically can range from 500 to 10,000 (e.g., 500 to 5,000), preferably from 1,000 to 8, 000 (e.g., 1,000 to 5,000) and most preferably from 1,500 to 6,000 (e.g., 1,500 to 3,000).
  • the functionalized polymers and/or derivatized polymers described herein having M n 's (g/mol) of greater than 10,000, preferably greater than 10,000 to 30,000 (preferably 20,000 to 30,000) are useful for viscosity index improvers for lubricating oil compositions, adhesive additives, antifogging and wetting agents, ink and paint adhesion promoters, coatings, tackifiers and sealants, and the like.
  • such polymers may be functionalized and derivatized to make multifunctional viscosity index improvers which also possess dispersant properties. (For more information please see US 6,022,929.)
  • the functionalized polymers and/or derivatized polymers described herein may be combined with other additives (such as viscosity index improvers, corrosion inhibitor, oxidation inhibitor, dispersant, lube oil flow improver, detergents, demulsifiers, rust inhibitors, pour point depressant, anti-foaming agents, antiwear agents, seal swellant, friction modifiers, and the like (described, for example, in US 6,022,929 at column 60, line 42 through column 78, line 54 and the references cited therein)) to form compositions for many applications, including but not limited to lube oil additive packages, lube oils, and the like.
  • additives such as viscosity index improvers, corrosion inhibitor, oxidation inhibitor, dispersant, lube oil flow improver, detergents, demulsifiers, rust inhibitors, pour point depressant, anti-foaming agents, antiwear agents, seal swellant, friction modifiers, and the like (described, for example, in
  • compositions containing these additives are typically are blended into the base oil in amounts which are effective to provide their normal attendant function. Representative effective amounts of such additives are illustrated as follows:
  • compositions (Typical) (Preferred)
  • Anti-Foaming Agents 0.001-0.1 0.001-1
  • Antiwear Agents 0.001-5 0.001-1.5
  • *Wt%'s are based on active ingredient content of the additive, and/or upon the total weight of any additive-package, or formulation which will be the sum of the A.I. weight of each additive plus the weight of total oil or diluent.
  • additive concentrates comprising concentrated solutions or dispersions of the subject additives of this invention (in concentrate amounts hereinabove described), together with one or more of said other additives (said concentrate when constituting an additive mixture being referred to herein as an additive-package) whereby several additives can be added simultaneously to the base oil to form the lubricating oil composition. Dissolution of the additive concentrate into the lubricating oil may be facilitated by solvents and by mixing accompanied with mild heating, but this is not essential.
  • the subject functionalized or derivatized polymers of the present invention can be added to small amounts of base oil or other compatible solvents along with other desirable additives to form additive-packages containing active ingredients in collective amounts of typically from about 2.5 to about 90%, and preferably from about 15 to about 75%, and most preferably from about 25 to about 60% by weight additives in the appropriate proportions with the remainder being base oil.
  • the final formulations may employ typically about 10 wt% of the additive-package with the remainder being base oil.
  • the functionalized polymers described herein can be reacted with an amount of one or more multifunctional coupling agents, e.g., trifunctional silane, triols, tricarboxylic acid, tricarbonyl chloride coupling agents or tetrafunctional coupling agents, under conditions sufficient to produce a dendritic hydrocarbon polymer.
  • a separate hydrogenation step is necessary to deliver substantially saturated polyolefins.
  • the one or more multifunctional coupling agents useful in the processes of this disclosure can be any trifunctional or tetrafunctional coupling agents, or coupling agents with functionalities equal to or greater than 3, that are capable of reacting with a telechelic hydrocarbon polymer.
  • Illustrative trifunctional coupling agents include, for example, trifunctional silanes, such as trichloromethylsilane, trichloroethoxysilane, 1 -dichloromethyl- 2-chlorodimethyl-disiloxane, l-dichloromethylsilyl-2-chlorodimethylsilyl ethane, or triols, such as glycerol, 1,3,5-benzenetriol, 1,2,6-hexanetriol, l, l, l-tris(hydroxymethyl)propane, or tricarboxylic acids and tricarbonyl chlorides, such as 1,2,4-benzenecarboxylic anhydride, 1,2,4-benzenecarboxylic acid, 1,3,5-benzenetricarboxylic acid, and trimesoyl chloride.
  • trifunctional silanes such as trichloromethylsilane, trichloroethoxysilane, 1 -dichloro
  • trifunctional silane coupling agents preferred ones are selected from within the structure X 3 Si(CH 2 ) n H or X 2 (CH 3 ) 2 Si— (CH 2 )n ⁇ Si(CH 3 ) 2 X, wherein n is greater than or equal to 0 and X is a halogen or an alkoxy, and Cl(CH 3 ) 2 Si-(CH 2 ) n -SiCl(CH 3 )-(CH 2 ) n - -SiCl(CH 3 ) 2 , wherein n is greater than or equal to 0.
  • Useful trifunctional coupling agents are disclosed, for example, in U.S. Pat. No. 5,360,875 and U.S. Patent Publication Nos. 2011/01 18420 and 2013/0172493, the disclosures of which are incorporated herein by reference in their entirety.
  • the functionalized polymers prepared herein can be used to produce dendritic or highly branched polymer which in turn is useful as a polymer additive.
  • dendritic or highly branched polymer is useful to modify ethylene polymers (such as linear low density polyethylene) as described in the Polyethylene Blends section below.
  • the functionalized polymer and or derivatized polymer produced herein is combined with one or more additional polymers prior to being formed into a film, molded part or other article.
  • additional polymers include polyethylene, isotactic polypropylene, highly isotactic polypropylene, syndiotactic polypropylene, random copolymer of propylene and ethylene, and/or butene, and/or hexene, polybutene, ethylene vinyl acetate, LDPE, LLDPE, HDPE, ethylene vinyl acetate, ethylene methyl acrylate, copolymers of acrylic acid, polymethylmethacrylate or any other polymers polymerizable by a high-pressure free radical process, polyvinylchloride, polybutene- 1, isotactic polybutene, ABS resins, ethylene-propylene rubber (EPR), vulcanized EPR, EPDM, block copolymer, styrenic block copoly
  • the functionalized polymer and derivatized polymer are present in the above blends, at from 10 to 99 wt%, based upon the weight of the polymers in the blend, preferably 20 to 95 wt%, even more preferably at least 30 to 90 wt%, even more preferably at least 40 to 90 wt%, even more preferably at least 50 to 90 wt%, even more preferably at least 60 to 90 wt%, even more preferably at least 70 to 90 wt%, with the balance being made up by the additional polymers.
  • the blends described above may be produced by mixing the polymers of the invention with one or more additional polymers (as described above), by connecting reactors together in series to make reactor blends or by using more than one catalyst in the same reactor to produce multiple species of polymer.
  • the polymers can be mixed together prior to being put into the extruder or may be mixed in an extruder.
  • the blends may be formed using conventional equipment and methods, such as by dry blending the individual components and subsequently melt mixing in a mixer, or by mixing the components together directly in a mixer, such as, for example, a Banbury mixer, a Haake mixer, a Brabender internal mixer, or a single or twin-screw extruder, which may include a compounding extruder and a side-arm extruder used directly downstream of a polymerization process, which may include blending powders or pellets of the resins at the hopper of the film extruder. Additionally, additives may be included in the blend, in one or more components of the blend, and/or in a product formed from the blend, such as a film, as desired.
  • a mixer such as, for example, a Banbury mixer, a Haake mixer, a Brabender internal mixer, or a single or twin-screw extruder, which may include a compounding extruder and a side-arm extruder used directly downstream of a polymerization
  • additives are well known in the art, and can include, for example: fillers; antioxidants (e.g., hindered phenolics such as IRGANOXTM 1010 or IRGANOXTM 1076 available from Ciba-Geigy); phosphites (e.g., IRGAFOSTM 168 available from Ciba-Geigy); anti-cling additives; tackifiers, such as polybutenes, terpene resins, aliphatic and aromatic hydrocarbon resins, alkali metal and glycerol stearates, and hydrogenated rosins; UV stabilizers; heat stabilizers; anti-blocking agents; release agents; anti-static agents; pigments; colorants; dyes; waxes; silica; fillers; talc; and the like.
  • antioxidants e.g., hindered phenolics such as IRGANOXTM 1010 or IRGANOXTM 1076 available from Ciba-Ge
  • the functionalized polymer and or dendritic or highly branched polymer produced herein can be blended with ethylene polymers to improve processability, bubble stability and physical properties of the ethylene polymer, such as haze and tensile strength.
  • this invention relates to polyethylene compositions comprising one or more ethylene polymers (preferably linear ethylene polymers) and one or more modifiers (also referred to as the "modifier” or the “branched modifier”).
  • this invention relates to a composition
  • a composition comprising:
  • a branching index, g' v j s (determined according to the procedure described in the Test Method section below) of 0.95 or more, preferably 0.97 or more, preferably 0.98 or more, preferably 0.99 or more;
  • a density of 0.860 to 0.980 g/cc (preferably from 0.880 to 0.940 g/cc, preferably from 0.900 to 0.935 g/cc, preferably from 0.910 to 0.930 g/cc);
  • an M w of 20,000 g/mol or more (preferably 20,000 to 2,000,000 g/mol, preferably 30,000 to 1,000,000 g/mol, more preferably 40,000 to 200,000 g/mol, preferably 50,000 to 750,000 g/mol); and
  • 16 kg 16 kg of less than 0.7 dg/min (preferably less than 0.6 dg/min, preferably less than 0.5 dg/min) and 2) a branching index, g' vjs , of less than 0.96, (preferably less than 0.95, preferably less than 0.90, preferably less than 0.85, preferably less than 0.80, preferably less than 0.75).
  • the ethylene polymer is selected from ethylene homopolymer, ethylene copolymers, and blends thereof.
  • Useful copolymers comprise one or more comonomers in addition to ethylene and can be a random copolymer, a statistical copolymer, a block copolymer, and/or blends thereof.
  • the ethylene polymer blends described herein may be physical blends or in situ blends of more than one type of ethylene polymer or blends of ethylene polymers with polymers other than ethylene polymers where the ethylene polymer component is the majority component (e.g., greater than 50 wt%).
  • the method of making the polyethylene is not critical, as it can be made by slurry, solution, gas phase, high pressure, or other suitable processes, and by using catalyst systems appropriate for the polymerization of polyethylenes, such as Ziegler-Natta-type catalysts, chromium catalysts, metallocene-type catalysts, other appropriate catalyst systems, or combinations thereof, or by free-radical polymerization.
  • the ethylene polymers are made by the catalysts, activators, and processes described in U.S. Patent Nos. 6,342,566; 6,384, 142; 5,741 ,563; PCT publications WO 03/040201 ; and WO 97/19991.
  • Such catalysts are well known in the art, and are described in, for example, ZIEGLER CATALYSTS (Gerhard Fink, Rolf Mulhaupt and Hans H. Brintzinger, eds., Springer- Verlag 1995); Resconi et al; and I, II METALLOCENE-BASED POLYOLEFINS (Wiley & Sons 2000).
  • Preferred ethylene polymers and copolymers that are useful in this invention include those sold by ExxonMobil Chemical Company in Houston Texas, including those sold as ExxonMobil HDPE, ExxonMobil LLDPE, and ExxonMobil LDPE; and those sold under the ENABLETM , EXACTTM, EXCEEDTM, ESCORENETM, EXXCOTM, ESCORTM, PAXONTM, and OPTEMATM tradenames.
  • the polyethylene copolymers preferably have a composition distribution breadth index (CDBI) of 60% or more, preferably 60% to 80%, preferably 65% to 80%.
  • CDBI composition distribution breadth index
  • the ethylene copolymer has a density of 0.910 to 0.950 g/cm 3 (preferably 0.915 to 0.940 g/cm 3 , preferably 0.918 to 0.925 g/cm 3 ) and a CDBI of 60% to 80%, preferably between 65% and 80%.
  • these polymers are metallocene polyethylenes (mPEs).
  • the ethylene copolymer comprises one or more mPEs described in U.S. Patent Application Publication No. 2007/0260016 and U.S. Patent No. 6,476, 171, e.g., copolymers of an ethylene and at least one alpha olefin having at least 5 carbon atoms obtainable by a continuous gas phase polymerization using supported catalyst of an activated molecularly discrete catalyst in the substantial absence of an aluminum alkyl based scavenger (e.g., triethylaluminum, trimethylaluminum, tri-isobutyl aluminum, tri-n- hexylaluminum, and the like), which polymer has a Melt Index of from 0.1 to 15 (ASTM D 1238, condition E); a CDBI of at least 70%, a density of from 0.910 to 0.930 g/cc; a Haze (ASTM D1003) value of less than 20; a Melt Index ratio (121/12,
  • Patent No. 6,255,426) of from 20,000 to 60,000 psi (13790 to 41369 N/cm 2 ); and a relation between M and the Dart Impact Strength (26 inch, ASTM D 1709) in g/mil (DIS) complying with the formula: DIS>0.8 x [100+e( 1 1 -71-0.000268xM+2.183xl0-9xM2) ]; where "e” represents 2.1783, the base Napierian logarithm, M is the averaged Modulus in psi and DIS is the 26 inch (66cm) dart impact strength. (See U.S. Patent No. 6,255,426 for further description of such ethylene polymers.)
  • the ethylene polymer comprises a Ziegler-Natta polyethylene, e.g., CDBI less than 50, preferably having a density of 0.910 to 0.950 g/cm 3 (preferably 0.915 to 0.940 g/cm 3 , preferably 0.918 to 0.925 g/cm 3 ).
  • the ethylene polymer comprises olefin block copolymers as described in EP 1 716 190.
  • the ethylene polymer is produced using chrome based catalysts, such as, for example, in U.S. Patent No. 7,491,776, including that fluorocarbon does not have to be used in the production.
  • chrome based catalysts such as, for example, in U.S. Patent No. 7,491,776, including that fluorocarbon does not have to be used in the production.
  • Commercial examples of polymers produced by chromium include the PaxonTM grades of polyethylene produced by ExxonMobil Chemical Company, Houston Texas.
  • the ethylene polymer comprises ethylene and an optional comonomer of propylene, butene, pentene, hexene, octene, nonene, or decene, and said polymer has a density of more than 0.86 to less than 0.910 g/cm 3 , an M w of 20,000 g/mol or more (preferably 50,000 g/mol or more) and a CDBI of 90% or more.
  • the ethylene polymer comprises substantially linear and linear ethylene polymers (SLEPs).
  • SEPs substantially linear and linear ethylene polymers
  • Substantially linear ethylene polymers and linear ethylene polymers and their method of preparation are fully described in U.S. Patent Nos. 5,272,236; 5,278,272; 3,645,992; 4,937,299; 4,701,432; 4,937,301 ; 4,935,397; 5,055,438; EP 129,368; EP 260,999; and WO 90/07526, which are fully incorporated herein by reference.
  • a linear or substantially linear ethylene polymer means a homopolymer of ethylene or a copolymer of ethylene and one or more alpha-olefin comonomers having a linear backbone (i.e. no cross linking), a specific and limited amount of long-chain branching or no long-chain branching, a narrow molecular weight distribution, a narrow composition distribution (e.g., for alpha-olefin copolymers) or a combination thereof. More explanation of such polymers is discussed in U.S. Patent No. 6,403,692, which is incorporated herein by reference for all purposes.
  • Preferred ethylene homopolymers and copolymers useful in this invention typically have:
  • T m of 30°C to 150°C, preferably 30°C to 140°C, preferably 50°C to 140°C, more preferably 60°C to 135°C, as determined by the DSC method described below in the Test Methods section;
  • the polyethylene may have a crystallinity of at least 30%, preferably at least 40%, alternatively at least 50%, where crystallinity is determined by the DSC method described below in the Test Methods section); and/or
  • a heat of fusion of 300 J/g or less, preferably 1 to 260 J/g, preferably 5 to 240 J/g, preferably 10 to 200 J/g, as measured by the DSC method described below in the Test Methods section; and/or 6.
  • a crystallization temperature (Tc) of 15°C to 130°C, preferably 20°C to 120°C, more preferably 25°C to 1 10°C, preferably 60°C to 125°C, as measured by the method described below in the Test Methods section; and/or
  • a heat deflection temperature of 30°C to 120°C, preferably 40°C to 100°C, more preferably 50°C to 80°C, as measured according to ASTM D648 on injection molded flexure bars, at 66 psi load (455kPa); and/or
  • a density of 0.860 to 0.980 g/cc (preferably from 0.880 to 0.940 g/cc, preferably from 0.900 to 0.935 g/cc, preferably from 0.910 to 0.930 g/cc) (alternately from 0.85 to 0.97 g/cm 3 , preferably 0.86 to 0.965 g/cm 3 , preferably 0.88 to 0.96 g/cm 3 , alternatively between 0.860 and 0.910 g/cm 3 , alternatively between 0.910 and 0.940 g/cm 3 , or alternatively between 0.94 to 0.965 g/ cm 3 ) (determined according to
  • the polyethylene may be an ethylene homopolymer, such as HDPE.
  • the ethylene homopolymer has a molecular weight distribution (M w /M n ) of up to 40, preferably ranging from 1.5 to 20, from 1.8 to 10 in another embodiment, from 1.9 to 5 in yet another embodiment, and from 2.0 to 4 in yet another embodiment.
  • the 1% secant flexural modulus (determined according to ASTM D-882-10) of the ethylene polymer falls in a range of 200 to 1000 MPa, from 300 to 800 MPa in another embodiment, and from 400 to 750 MPa in yet another embodiment, wherein a desirable polymer may exhibit any combination of any upper flexural modulus limit with any lower flexural modulus limit.
  • the melt index (MI) of preferred ethylene homopolymers range from 0.05 to 800 dg/min in one embodiment and from 0.1 to 100 dg/min in another embodiment, as measured according to ASTM D1238 (190°C, 2.16 kg).
  • the polyethylene comprises less than 20 mol% propylene units (preferably less than 15 mol%, preferably less than 10 mol%, preferably less than 5 mol%, preferably 0 mol% propylene units).
  • the ethylene polymer is an ethylene copolymer, either random or block, of ethylene and one or more comonomers selected from C3 to C20 a-olefins, typically from C3 to a-olefins in another embodiment.
  • the comonomers are present from 0.1 wt% to 50 wt% of the copolymer in one embodiment, from 0.5 wt% to 30 wt% in another embodiment, from 1 wt% to 15 wt% in yet another embodiment, and from 0.1 wt% to 5 wt% in yet another embodiment, wherein a desirable copolymer comprises ethylene and C3 to C20 a-olefin derived units in any combination of any upper wt% limit with any lower wt% limit described herein.
  • the ethylene copolymer will have a weight average molecular weight of from greater than 8,000 g/mol in one embodiment, greater than 10,000 g/mol in another embodiment, greater than 12,000 g/mol in yet another embodiment, greater than 20,000 g/mol in yet another embodiment, and less than 1,000,000 g/mol in yet another embodiment, less than 800,000 g/mol in yet another embodiment, wherein a desirable copolymer may comprise any upper molecular weight limit with any lower molecular weight limit described herein.
  • the ethylene copolymer comprises ethylene and one or more other monomers selected from the group consisting of C3 to C20 linear, branched or cyclic monomers, and in some embodiments is a C3 to linear or branched alpha-olefin, preferably butene, pentene, hexene, heptene, octene, nonene, decene, dodecene, 4-methyl- pentene-1, 3 -methyl pentene- 1, 3,5,5-trimethyl-hexene-l , and the like.
  • the monomers may be present at up to 50 wt%, preferably from 0 wt% to 40 wt%, more preferably from 0.5 wt% to 30 wt%, more preferably from 2 wt% to 30 wt%, more preferably from 5 wt% to 20 wt%.
  • Preferred linear alpha-olefins useful as comonomers for the ethylene copolymers useful in this invention include C3 to Cg alpha-olefins, more preferably 1 -butene, 1 -hexene, and 1 -octene, even more preferably 1 -hexene.
  • Preferred branched alpha-olefins include 4-methyl- 1 -pentene, 3 -methyl- 1 -pentene, 3,5,5-trimethyl-l -hexene, and 5 -ethyl- 1 -nonene.
  • the ethylene polymer used herein is a plastomer having a density of 0.91 g/cm 3 or less, as determined by ASTM D1505, and a melt index (MI) between 0.1 and 50 dg/min, as determined by ASTM D1238 (190°C, 2.16 kg).
  • the useful plastomer is a copolymer of ethylene and at least one C3 to a-olefin, preferably C4 to Cg a-olefins.
  • the amount of C3 to a-olefin present in the plastomer ranges from 2 wt% to 35 wt% in one embodiment, from 5 wt% to 30 wt% in another embodiment, from 15 wt% to 25 wt% in yet another embodiment, and from 20 wt% to 30 wt% in yet another embodiment.
  • Preferred plastomers useful in the invention have a melt index of between 0.1 and 40 dg/min in one embodiment, from 0.2 to 20 dg/min in another embodiment, and from 0.5 to 10 dg/min in yet another embodiment.
  • the average molecular weight of preferred plastomers ranges from 10,000 to 800,000 g/mole in one embodiment and from 20,000 to 700,000 g/mole in another embodiment.
  • the 1% secant flexural modulus (ASTM D-882-10) of preferred plastomers ranges from 5 MPa to 100 MPa in one embodiment and from 10 MPa to 50 MPa in another embodiment.
  • preferred plastomers that are useful in compositions of the present invention have a melting temperature (T m ) of from 30°C to 100°C in one embodiment and from 40°C to 80°C in another embodiment.
  • T m melting temperature
  • the degree of crystallinity of preferred plastomers is between 3% and 30%.
  • Particularly preferred plastomers useful in the present invention are synthesized using a single-site catalyst, such as a metallocene catalyst; comprise copolymers of ethylene and higher a-olefins such as propylene, 1-butene, 1-hexene, and 1-octene, and which contain enough of one or more of these comonomer units to yield a density between 0.86 and 0.91 g/cm 3 in one embodiment.
  • the molecular weight distribution (M w /M n ) of desirable plastomers ranges from 1.5 to 5 in one embodiment and from 2.0 to 4 in another embodiment.
  • Examples of commercially available plastomers are EXACTTM 4150, a copolymer of ethylene and 1 -hexene, the 1 -hexene derived units making up from 18 wt% to 22 wt% of the plastomer and having a density of 0.895 g/cm 3 and MI of 3.5 dg/min (ExxonMobil Chemical Company, Houston, TX); EXACTTM 8201, a copolymer of ethylene and 1-octene, the 1-octene derived units making up from 26 wt% to 30 wt% of the plastomer; and having a density of 0.882 g/cm 3 and MI of 1.0 dg/min (ExxonMobil Chemical Company, Houston, TX).
  • the melt index (MI) of preferred ethylene polymers ranges from 0.02 dg/min to 800 dg/min in one embodiment, from 0.05 to 500 dg/min in another embodiment, and from 0.1 to 100 dg/min in another embodiment.
  • the polyethylene has a MI of 20 dg/min or less, 7 dg/min or less, 5 dg/min or less, or 2 dg/min or less, or less than 2 dg/min.
  • the polymer has a Mooney viscosity, ML(l+4) @ 125°C (measured according to ASTM D 1646) of 100 or less, 75 or less, 60 or less, or 30 or less.
  • a process to produce a functionalized polymer comprising:
  • oxidizing agent is one or more of a persulfate, hemi persulfate, persulfate salt, hydrogen peroxide, hydroperoxide (such as cumene hydroperoxide,) acyl peroxide or a peroxymonosulfate.
  • step c) is from 0.5 : 1 to 10: 1 , preferably 1 : 1 to 1 :8, preferably 2 : 1 to 4: 1 .
  • phase transfer catalyst is a quaternary ammonium salt or a phosphonium salt.
  • a process to produce a functionalized polymer comprising:
  • the first polymer having internal or terminal unsaturation(s) is a polydiene or a vinyl or vinylidene terminated macromonomer (VTM).
  • VTM vinyl or vinylidene terminated macromonomer
  • phase transfer catalyst is a quaternary ammonium salt or a phosphonium salt.
  • a process to produce a functionalized polymer comprising contacting a first polymer comprising a vinyl terminated macromonomer (VTM) having an M n of at least 50 g/mol as determined by GPC with an oxidizing agent comprising an iodine containing compound and an optional phase transfer catalyst to obtain a functionalized polymer.
  • VTM vinyl terminated macromonomer
  • phase transfer catalyst is a quaternary ammonium salt or phosphonium salt.
  • polymer molecular weight (weight-average molecular weight, M w , number-average molecular weight, M n , and Z-averaged molecular weight, M z ) and molecular weight distribution (M w /M n ) are determined using Gel Permeation Chromatography-Size-Exclusion Chromatography.
  • Equipment consists of a High Temperature Size Exclusion Chromatograph (either from Waters Corporation or Polymer Laboratories), with a differential refractive index detector (DRI), an online light scattering detector, and a viscometer. Three Polymer Laboratories PLgel 10mm Mixed-B columns are used.
  • the nominal flow rate is 0.5 cm 3 /min and the nominal injection volume is 300 ⁇ ⁇ .
  • the various transfer lines, columns and differential refractometer (the DRI detector) are contained in an oven maintained at 135°C.
  • Solvent for the SEC experiment is prepared by dissolving 6 grams of butylated hydroxy toluene as an antioxidant in 4 liters of reagent grade 1,2,4 trichlorobenzene (TCB). The TCB mixture is then filtered through a 0.7 ⁇ glass pre- filter and subsequently through a 0.1 ⁇ Teflon filter. The TCB is then degassed with an online degasser before entering the SEC.
  • Polymer solutions are prepared by placing dry polymer in a glass container, adding the desired amount of TCB, then heating the mixture at 160°C with continuous agitation for about 2 hours. All quantities are measured gravimetrically.
  • the TCB densities used to express the polymer concentration in mass/volume units are 1.463 g/ml at room temperature and 1.324 g/ml at 135°C.
  • the injection concentration can range from 1.0 to 2.0 mg/ml, with lower concentrations being used for higher molecular weight samples.
  • the processes of subtracting the prevailing baseline (i.e., background signal) and setting integration limits that define the starting and ending points of the chromatogram are well known to those familiar with SEC analysis. Units on parameters throughout this description of the SEC method are such that concentration is expressed in g/cm 3 , molecular weight is expressed in g/mole, and intrinsic viscosity is expressed in dL/g.
  • the light scattering detector is a Wyatt Technology High Temperature mini- DAW .
  • the polymer molecular weight, M, at each point in the chromatogram is determined by analyzing the LS output using the Zimm model for static light scattering (M.B. Huglin, LIGHT SCATTERING FROM POLYMER SOLUTIONS, Academic Press, 1971):
  • AR(Q) is the measured excess Rayleigh scattering intensity at scattering angle ⁇
  • c is the polymer concentration determined from the DRI analysis
  • a 2 is the second virial coefficient
  • ⁇ ( ⁇ ) is the form factor for a monodisperse random coil (described in the above reference)
  • K 0 is the optical constant for the system:
  • the molecular weight determined by LS analysis is calculated by solving the above equations for each point in the chromatogram; together these allow for calculation of the average molecular weight and molecular weight distribution by LS analysis.
  • a high temperature Viscotek Corporation viscometer is used, which has four capillaries arranged in a Wheatstone bridge configuration with two pressure transducers. One transducer measures the total pressure drop across the detector, and the other, positioned between the two sides of the bridge, measures a differential pressure.
  • the specific viscosity for the solution flowing through the viscometer at each point in the chromatogram, (r ⁇ s , is calculated from the ratio of their outputs.
  • the intrinsic viscosity at each point in the chromatogram, [r ⁇ , is calculated by solving the following equation (for the positive root) at each point i:
  • the branching index (g' v i s ) is calculated using the output of the SEC-DRI-LS-VIS method (described above) as follows.
  • ] aV g, of the sample is calculated by:
  • [ ⁇ ] ⁇ Cl Ml where the summations are over the chromatographic slices, i, between the integration limits.
  • the hydrogenated polybutadiene based modifier can be represented as a butene copolymer for these calculations with 12% butene.
  • M v is the viscosity-average molecular weight based on molecular weights determined by LS analysis.
  • Proton NMR spectra were collected using a 500 MHz Varian pulsed fourier transform NMR spectrometer equipped with a variable temperature proton detection probe operating at 120°C.
  • the polymer sample is dissolved in l, l,2,2-tetrachloroethane-d2 (TCE- d2) and transferred into a 5 mm glass NMR tube.
  • samples are prepared by adding about 0.3 g sample to approximately 3 g of tetrachloroethane-d2 in a 10 mm NMR tube.
  • the samples are dissolved and homogenized by heating the tube and its contents to 150°C.
  • the data are collected using a Varian spectrometer, with corresponding X H frequencies of either 400 or 700 MHz (in event of conflict, 700 MHz shall be used).
  • the data are acquired using nominally 4000 transients per data file with a about a 10 second pulse repetition delay.
  • multiple data files may be added together.
  • the spectral width was adjusted to include all the NMR resonances of interest and FIDs were collected containing a minimum of 32K data points.
  • the samples are analyzed at 120°C in a 10 mm broad band probe.
  • Peak melting point, Tm, (also referred to as melting point), peak crystallization temperature, Tc, (also referred to as crystallization temperature), glass transition temperature (Tg), heat of fusion (AHf or Hf), and percent crystallinity were determined using the following DSC procedure according to ASTM D3418-03.
  • Differential scanning calorimetric (DSC) data were obtained using a TA Instruments model Q200 machine. Samples weighing approximately 5 mg to 10 mg were sealed in an aluminum hermetic sample pan. The DSC data were recorded by first gradually heating the sample to 200°C at a rate of 10°C/minute.
  • the sample was kept at 200°C for 2 minutes, then cooled to -90°C at a rate of 10°C/minute, followed by an isothermal for 2 minutes and heating to 200°C at 10°C/minute. Both the first and second cycle thermal events were recorded. Areas under the endothermic peaks were measured and used to determine the heat of fusion and the percent of crystallinity. The percent crystallinity is calculated using the formula, [area under the melting peak (Joules/gram) / B (Joules/gram)] * 100, where B is the heat of fusion for the 100% crystalline homopolymer of the major monomer component.
  • a flask was charged with 9.9652 g (0.1845 mol butadiene repeating units) of a cis-1,4- polybutadiene (obtained from Aldrich) and 125 mL toluene at 60°C under an inert nitrogen atmosphere. Upon dissolution, 94 mL of water was added. The biphasic mixture was stirred and 0.0128 g crosslinked iodo-polystyrene (obtained from Aldrich) was added to the reaction mixture.
  • the reaction mixture was made slightly acidic upon the addition of 1 M HC1 aqueous solution.
  • the solution was concentrated down to 4 mL.
  • the concentrated solution was then added slowly to a stirring 500 mL methanol to induce precipitation.
  • the white solid was filtered, affording a hydrogenated PBd (denoted as "h-PBd") after dried overnight in a 40°C vacuum oven.
  • X H NMR of the product indicated the product h-c-PBd was fully saturated and contained a triplet peak that is the signature of CH 2 next to carboxylic acid. This peak did not exist in the starting material cis-1,4- polybutadiene.
  • the hydrogenated cis-l,4-polybutadiene had an M n of 96,000 g/mol and an M w of 273,000 g/mol.
  • the hydrogenated cleaved product (h-c-PBd) has an M n of 58,000 g/mol and an M w of 126,000 g/mol.
  • reaction mixture was slowly added dropwise to a stirring solution of 1 L methanol containing a small amount of 1M HC1 aqueous solution.
  • the solvent was decanted and the brown solid transformed into a dark brown viscous solid upon drying at 40°C under vacuum.
  • the total cleaved product c-PBd was 0.6 g (60% yield).
  • compositions, an element or a group of elements are preceded with the transitional phrase “comprising”, it is understood that we also contemplate the same composition or group of elements with transitional phrases “consisting essentially of,” “consisting of, “selected from the group of consisting of,” or “is” preceding the recitation of the composition, element, or elements and vice versa.

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Abstract

Cette invention concerne un procédé de production d'un polymère fonctionnalisé comprenant : a) la mise en contact d'un polymère aromatique iodé avec un agent oxydant pour obtenir un sel d'iodonium du polymère aromatique ; b) la mise en contact du sel d'iodonium du polymère aromatique avec un polymère portant une ou des insaturations internes ou terminales ; et c) l'obtention d'un polymère fonctionnalisé à partir du polymère portant une ou des insaturations internes ou terminales, le polymère fonctionnalisé ayant une Mn inférieure à la Mn du polymère portant une ou des insaturations internes ou terminales et le polymère fonctionnalisé ayant un indice d'acide supérieur à l'indice d'acide du polymère portant une ou des insaturations internes ou terminales.
PCT/US2014/066876 2013-12-19 2014-11-21 Procédé de production d'un polymère fonctionnalisé WO2015094580A1 (fr)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3285949A (en) * 1964-04-17 1966-11-15 Goodrich Co B F Carboxyl-terminated butadiene polymers prepared in tertiary butanol with bis-azocyano acid initiation
US5115019A (en) * 1990-03-30 1992-05-19 Shell Oil Company Carboxy-functional hydrogenated block copolymer dispersed in epoxy resin
US5844050A (en) * 1993-07-30 1998-12-01 Nippon Zeon Co., Ltd. Modified conjugated diene polymer, process for producing same and composition comprising same
US6784256B1 (en) * 1997-10-23 2004-08-31 Noveon Ip Holdings Corp. End-functionalized polymers by controlled free-radical polymerization process and polymers made therefrom

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3285949A (en) * 1964-04-17 1966-11-15 Goodrich Co B F Carboxyl-terminated butadiene polymers prepared in tertiary butanol with bis-azocyano acid initiation
US5115019A (en) * 1990-03-30 1992-05-19 Shell Oil Company Carboxy-functional hydrogenated block copolymer dispersed in epoxy resin
US5844050A (en) * 1993-07-30 1998-12-01 Nippon Zeon Co., Ltd. Modified conjugated diene polymer, process for producing same and composition comprising same
US6784256B1 (en) * 1997-10-23 2004-08-31 Noveon Ip Holdings Corp. End-functionalized polymers by controlled free-radical polymerization process and polymers made therefrom

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
KIRSCHNING, ANDREAS ET AL.: "Functionalized polymers-emerging versatile tools for solution-phase chemistry and automated parallel synthesis.", ANGEWANDTE CHEMIE INTERNATIONAL EDITION., vol. 40, no. ISS. 4, 2001, pages 650 - 679 *

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