IP Library Granted Patent US 7,662,901
Granted Patent B2
US 7,662,901 · App. 11/998,583 · Granted Feb 16, 2010

High crystallinity, high melt flow rate polypropylene

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Quick Facts
Patent No.
US 7,662,901
App. No.
11/998,583
Granted
Feb 16, 2010
Kind
B2
Abstract

The present invention is directed to a high melt flow rate high crystallinity polypropylene homopolymer. The present invention likewise describes a bulk polymerization process using a Ziegler-Natta catalyst to produce the high melt flow rate high crystallinity polypropylene homopolymer according to the invention.

Claims (12)

1. A composition comprising: a propylene homopolymer produced in a bulk polymerization process in the presence of a Ziegler-Natta catalyst comprising a first internal donor, a second internal donor, and an external donor, wherein the first internal donor is a phthalate and the second internal donor is one of a diether or a succinate, further wherein the external donor is selected from the group consisting of cyclohexylmethyldimethoxysilane, cyclohexylethyldimethoxysilane, diphenyldimethoxysilane, phenyltriethoxysilane, 3,3,3-trifluoropropylmethyldimethoxysilane, diisopropyldimethoxysilane, octylmethyldimethoxysilane, isobutyltrimethoxysilane, isobutyltriethoxysilane, n-propyltrimethoxysilane, di-t-butyldimethoxysilane, cyclopentyl 1,1-dimethyl-2,2-dimethylethyldimethoxysilane and diamino silanes, the propylene homopolymer having a xylene soluble content of less than 2 percent, and a xylene insoluble fraction having a meso pentad content of greater than 96 percent and an average meso run length of at least 140, the propylene homopolymer having a melt flow rate of at least to 20 dg/min but less than 60 dg/min.

2. The composition according to claim 1 , wherein the propylene homopolymer when nucleated has a flexural modulus of greater than about 285,000 psi and tensile yield stress of greater than 5,800 psi.

3. The composition according to claim 1 , wherein the ratio of the first internal donor to the second internal donor is from 95:5 to 5:95 by weight.

4. A process for producing a high crystallinity, high melt flow rate propylene homopolymer comprising: polymerizing propylene in a bulk process in the presence of a Ziegler-Natta catalyst comprising a first internal donor, a second internal donor, and an external donor, wherein the first internal donor is a phthalate and the second internal donor is one of a diether or a succinate, further wherein the external donor is selected from the group consisting of cyclohexylmethyldimethoxysilane, cyclohexylethyldimethoxysilane, diphenyldimethoxysilane, phenyltriethoxysilane, 3,3,3-trifluoropropylmethyldimethoxysilane, diisopropyldimethoxysilane, octylmethyldimethoxysilane, isobutyltrimethoxysilane, isobutyltriethoxysilane, n-propyltrimethoxysilane, di-t-butyldimethoxysilane, cyclopentyl 1,1-dimethyl-2,2-dimethylethyldimethoxysilane and diamino silanes, to produce a propylene homopolymer having a xylene soluble content of less than 2 percent, and a xylene insoluble fraction having a meso pentad content of greater than 96 percent and an average meso run length of at least 140, the propylene homopolymer having a melt flow rate of at least 20 dg/min but less than 60 dg/min.

5. The process according to claim 4 , wherein the external donor is cyclohexylmethyldimethoxysilane.

6. The process according to claim 4 , wherein the ratio of the first internal donor to the second internal donor is from 95:5 to 5:95 by weight.

7. A propylene homopolymer having a xylene soluble content of less than 2 percent, a xylene insoluble fraction having a meso pentad content of greater than 96 percent and an average meso run length of at least 140, and a melt flow rate of at least 20 dg/min but less than 60 dg/min, wherein said propylene homopolymer is prepared by a process comprising polymerizing propylene in a bulk process in the presence of a Ziegler-Natta catalyst comprising a first internal donor, a second internal donor, and an external donor, wherein the first internal donor is a phthalate and the second internal donor is one of a diether or a succinate, further wherein the external donor is selected from the group consisting of cyclohexylmethyldimethoxysilane, cyclohexylethyldimethoxysilane, diphenyldimethoxysilane, phenyltriethoxysilane, 3,3,3-trifluoropropylmethyldimethoxysilane, diisopropyldimethoxysilane, octylmethyldimethoxysilane, isobutyltrimethoxysilane, isobutyltriethoxysilane, n-propyltrimethoxysilane, di-t-butyldimethoxysilane, cyclopentyl 1,1-dimethyl-2,2-dimethylethyldimethoxysilane and diamino silanes.

8. The propylene homopolymer according to claim 7 , wherein the external donor is cyclohexylmethyldimethoxysilane.

9. The propylene homopolymer according to claim 7 , wherein the ratio of the first internal donor to the second internal donor is from 95:5 to 5:95 by weight.

10. A method for producing a reactor grade copolymer comprising a high crystallinity, high melt flow rate propylene homopolymer, said method comprising: polymerizing propylene in a bulk process in a first reactor in the presence of a Ziegler-Natta catalyst comprising a first internal donor, a second internal donor, and an external donor, wherein the first internal donor is a phthalate and the second internal donor is one of a diether or a succinate, further wherein the external donor is selected from the group consisting of cyclohexylmethyldimethoxysilane, cyclohexylethyldimethoxysilane, diphenyldimethoxysilane, phenyltriethoxysilane, 3,3,3-trifluoropropylmethyldimethoxysilane, diisopropyldimethoxysilane, octylmethyldimethoxysilane, isobutyltrimethoxysilane, isobutyltriethoxysilane, n-propyltrimethoxysilane, di-t-butyldimethoxysilane, cyclopentyl 1,1-dimethyl-2,2-dimethylethyldimethoxysilane and diamino silanes, to produce a propylene homopolymer having a xylene soluble content of less than 2 percent, and a xylene insoluble fraction having a meso pentad content of greater than 96 percent and an average meso run length of at least 140, the propylene homopolymer having a melt flow rate of at least 20 dg/min but less than 60 dg/min, and transferring said homopolymer to a second reactor wherein a copolymerization takes place with a comonomer selected from the group consisting of C 2 to C 6 alkenes other than propylene.

11. The method according to claim 10 , wherein the external donor is cyclohexylmethyldimethoxysilane.

12. A reactor grade copolymer comprising a propylene homopolymer having a xylene soluble content of less than 2 percent, a xylene insoluble fraction having a meso pentad content of greater than 96 percent and an average meso run length of at least 140, and a melt flow rate of at least 20 dg/min but less than 60 dg/min, wherein said homopolymer is prepared by a process comprising polymerizing propylene in a bulk process in the presence of a Ziegler-Natta catalyst comprising a first internal donor, a second internal donor, and an external donor, wherein the first internal donor is a phthalate and the second internal donor is one of a diether or a succinate, further wherein the external donor is selected from the group consisting of cyclohexylmethyldimethoxysilane, cyclohexylethyldimethoxysilane, diphenyldimethoxysilane, phenyltriethoxysilane, 3,3,3-trifluoropropylmethyldimethoxysilane, diisopropyldimethoxysilane, octylmethyldimethoxysilane, isobutyltrimethoxysilane, isobutyltriethoxysilane, n-propyltrimethoxysilane, di-t-butyldimethoxysilane, cyclopentyl 1,1-dimethyl-2,2-dimethylethyldimethoxysilane and diamino silanes.

Assignments (4)
MERGER Recorded Jan 10, 2011
From: BRASKEM PP AMERICAS, INC.
To: BRASKEM AMERICA, INC.
Reel/Frame 025604/0572 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 17, 2010
From: SUNOCO, INC. (R&M)
To: SUNOCO CHEMICALS, INC.
Reel/Frame 025379/0866 →
CHANGE OF NAME Recorded Nov 17, 2010
From: SUNOCO CHEMICALS, INC.
To: BRASKEM PP AMERICAS, INC.
Reel/Frame 025379/0895 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 19, 2009
From: SUNOCO, INC. (R&M)
To: SUNOCO CHEMICALS, INC.
Reel/Frame 023544/0271 →