High modulus, high ductility polyolefins

1. A polymer that comprises a polypropylene homopolymer portion and an EP rubber portion interspersed therein, further comprising:

a) a flexural modulus value of any value in the range of 140 to 215 Kpsi;

b) an instrumented impact ductile failure at −30° C. and 6.7 m/s;

c) an EP rubber content of any amount in the range of 18.00-26.00% by weight, including every hundredth percentage therebetween based upon the total weight of said polymer;

d) a melt flow rate in the range of any value in the range of 10.00 to 40.00 grams per 10 minutes, including every hundredth gram per 10 minutes therebetween;

e) a xylene-soluble fraction content of the homopolymer portion of any value in the range of 1.00 to 2.50%, including every hundredth percentage therebetween; and

f) a total ethylene content of any amount in the range of 15.00 to 20.00 molar percent, including every hundredth molar percentage therebetween.

2. A polymer according to claim 1 having a flexural modulus of any value in the range of 140 to 195 Kpsi.

3. A polymer according to claim 1 having an EP rubber content of at least 20% by weight based upon the total weight of said polymer.

4. A polymer according to claim 1 having a melt flow rate in the range of any value in the range of 10.00 to 35.00 grams per 10 minutes, including every hundredth gram per 10 minutes therebetween.

5. A polymer according to claim 1 having a melt flow rate in the range of any value in the range of 20.00 to 30.00 grams per 10 minutes, including every hundredth gram per 10 minutes therebetween.

6. A process for producing a predominantly polypropylene polymer having a flexural modulus value of any value in the range of 140 to 215 Kpsi; an instrumented impact ductile failure at −30° C. and 6.7 m/s; an EP rubber content of any amount in the range of 18-26% by weight based on the total weight of said polymer; a melt flow rate in the range of any value in the range of 10.00 to 35.00 grams per 10 minutes, including every hundredth gram therebetween; an EP rubber fraction having intrinsic viscosity of 2.1 to 2.8 dL/g, said process comprising:

a) providing first stage, second stage, third stage, and copolymer stage reactors each having an inlet and an outlet, wherein the outlet of said first, second and third stage reactors are in selectable fluid contact with the inlets of each of said second, third, and copolymer stage reactors, respectively;

b) providing propylene, hydrogen, a polymerization catalyst, a co-catalyst, and an external donor to said first stage reactor sufficient to provide a first propylene polymer having a Melt Flow Rate of at least 400 grams per 10 min.;

c) transmitting the polymer produced in the first stage reactor to said second stage reactor;

d) providing propylene to said second stage reactor sufficient to provide a second propylene polymer having a Melt Flow Rate in the range of about 100 to 800 grams per 10 min.;

e) transmitting the polymer produced in the second stage reactor to said third stage reactor;

f) providing propylene to said third stage reactor sufficient to provide a third propylene polymer having a Melt Flow Rate in the range of about 20 to 200 grams per 10 min.;

g) transmitting the polymer produced in the third stage reactor to said copolymer reactor;

h) producing a final polymer product by providing propylene, ethylene, and hydrogen to said copolymer reactor sufficient to incorporate ethylene-propylene rubber into said third propylene polymer in an amount in the range of 18.00% to 26.00%, including every hundredth percentage therebetween, based upon the total weight of said final polymer when it exits said copolymer reactor, said final propylene polymer having a Melt Flow Rate in the range of about 10-35 grams per 10 min.; and

i) collecting said final polymer from said outlet of said copolymer reactor.

7. A process according to claim 6 wherein said catalyst comprises a diether component which is a 2,2-dialkyl-1,3-dimethoxypropane.

8. A process according to claim 6 wherein said catalyst comprises a diether component selected from the group consisting of: 2,2-diisobutyl-1,3-dimethoxypropane; 2-isopropyl-2-isopentyl-1,3-dimethoxypropane; and 2,2-bis(cyclohexylmethyl)-1,3-dimethoxypropane.

9. A process according to claim 6 in which said cocatalyst is an aluminum trialkyl.

10. A process according to claim 9 wherein said aluminum trialkyl is selected from the group consisting of an aluminum compound in which an aluminum atom has three alkyl groups bonded to it, and mixtures of aluminum trialkyl and aluminum alkyl,

wherein said three alkyl groups attached to the aluminum atom are each independently selected from the group consisting of: methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, isobutyl, pentyl, 2-pentyl, 3-pentyl, neopentyl, and n-hexyl; and

wherein said aluminum alkyl is selected from the group consisting of alkyl-Al halides,

alkyl-Al hydrides, and alkyl-Al sesquichlorides.

11. A process according to claim 10 in which the aluminum trialkyl is triethyl aluminum.

12. A process according to claim 6 in which said external donor is an organosilane compound.

13. A process according to claim 12 in which said organosilane compound is dicyclopentyldimethoxysilane.

14. A process according to claim 6 in which said external donor is dicyclopentyldimethoxysilane, said co-catalyst is triethyl aluminum, said catalyst comprises a diether component, and the melt flow rate of the final propylene polymer is any value in the range of about 10-35 grams per 10 min. and further comprising the steps of:

j) adding an anti-oxidant to said final polymer; and

k) forming said final polymer into pellets.

15. A process according to claim 14 in which said diether component is selected from the group consisting of: 2,2-diisobutyl-1,3-dimethoxypropane; 2-isopropyl-2-isopentyl-1,3-dimethoxypropane; and 2,2-bis(cyclohexylmethyl)-1,3-dimethoxypropane.

16. A process for producing a molded article for a motor vehicle comprising the steps of:

a) providing a reactor-grade thermoplastic olefin polymer that comprises a polypropylene homopolymer portion and an EP rubber portion interspersed therein, further comprising:

i) a flexural modulus value of any value in the range of 140 to 215 Kpsi;

ii) an instrumented impact ductile failure at −30° C. and 6.7 m/s;

iii) an EP rubber content of any amount in the range of 18.00-26.00% by weight, including every hundredth percentage therebetween based upon the total weight of said polymer;

iv) a melt flow rate in the range of any value in the range of 10.00 to 35.00 grams per 10 minutes, including every hundredth gram per 10 minutes therebetween;

v) a xylene-soluble fraction content of the homopolymer portion of any value in the range of 1.00 to 2.50%, including every hundredth percentage therebetween; and

vi) a total ethylene content of any amount in the range of 15.00 to 20.00 molar percent, including every hundredth molar percentage therebetween;

b) providing a mold;

c) determining the degree of shrinkage desired for a selected set of molding conditions;

d) molding said article using said selected set of molding conditions.

17. A process according to claim 16 wherein said molded article is selected from the group consisting of bumpers, fascias, or interior head impact parts.

18. A process according to claim 16 wherein said molded article is produced by injection molding.

19. A molded article produced using the process of claim 16 , wherein said molded article is selected from the group consisting of: bumpers, fascias, or interior head impact parts.

20. A reaction scheme for producing a polymer having the physical properties set forth in claim 1 , said reaction scheme comprising:

a) producing a polyolefin polymer in a first liquid pool reactor by reacting propylene monomer in the presence of a Ziegler-Natta polymerization catalyst;

b) conveying said polymer produced in said first liquid pool reactor to a second liquid pool reactor, and admitting propylene monomer to said second liquid pool reactor in the presence of a Ziegler-Natta polymerization catalyst;

c) conveying said polymer produced in said second liquid pool reactor to a first gas-phase reactor, and admitting propylene monomer to said first gas-phase reactor in the presence of a Ziegler-Natta polymerization catalyst;

d) conveying said polymer produced in said first gas-phase reactor to a second gas-phase reactor, and admitting propylene monomer and ethylene monomer to said second gas-phase reactor in the presence of a Ziegler-Natta polymerization catalyst.

21. A polymer produced according to the reaction scheme of claim 20 , wherein the polymer produced has a melt flow rate of any value in the range of 10 to 35 grams per 10 minutes.