Single site catalyst supportation

1. A single site catalyst system comprising:

(a) a single site catalyst precursor compound;

(b) an activator; and

(c) a support having an average particle size of more than 30 μm up to 200 μm, a specific surface area of 400 m 2 /g or more, a pore volume of from 0.5 to 2 mL/g, and a mean pore diameter of from 1 to 20 nm (10 to 200 Å), the support comprising agglomerates of a plurality of primary particles wherein the primary particles have an average particle size from 1 nm to 50 μm;

(d) a polypropylene matrix having a porosity of at least 15%, and a volume average median pore diameter of less than 165 μm, as determined by mercury intrusion porosimetry; and

(e) active catalyst sites distributed in the matrix.

2. The catalyst system of claim 1 , wherein the average particle size is more than 50 μm, and the specific surface area is less than 1000 m 2 /g.

3. The catalyst system of claim 1 , wherein the specific surface area is more than 650 m 2 /g, the mean pore diameter is less than 7 nm (70 Å), and the activator comprises methylalumoxane.

4. The catalyst system of claim 1 , wherein the support material has a mean pore diameter of more than 7 nm (70 Å).

5. The catalyst system of claim 1 , wherein the primary particles have an average particle size from 1 nm to less than 30 μm.

6. The catalyst system of claim 1 , wherein the agglomerates are at least partially encapsulated.

7. The catalyst system of claim 1 , wherein the support comprises spray dried silica.

8. The catalyst system of claim 1 , wherein the activator comprises methylalumoxane.

9. The catalyst system of claim 1 , further comprising a co-activator selected from the group consisting of: trialkylaluminum, dialkylmagnesium, alkylmagnesium halide, and dialkylzinc.

10. The catalyst system of claim 1 , wherein the single site catalyst precursor compound is selected from precursor compounds I and II;

wherein precursor compound I is represented by the following formula:

(Cp) m R A n M 4 Q k

wherein:

each Cp is a cyclopentadienyl moiety or a substituted cyclopentadienyl moiety substituted by one or more hydrocarbyl radicals having from 1 to 20 carbon atoms;

R A is a structural bridge between two Cp moieties;

M 4 is a transition metal selected from groups 4 or 5;

Q is a hydride or a hydrocarbyl group having from 1 to 20 carbon atoms or an alkenyl group having from 2 to 20 carbon atoms, or a halogen;

m is 1, 2, or 3, with the proviso that if m is 2 or 3, each Cp may be the same or different;

n is 0 or 1, with the proviso that n=0 if m=1; and

k is such that k+m is equal to the oxidation state of M 4 , with the proviso that if k is greater than 1, each Q may be the same or different; and

wherein precursor compound II is represented by the following formula:

R A (CpR″ p )(CpR* q )M 5 Q r

wherein:

each Cp is a cyclopentadienyl moiety or substituted cyclopentadienyl moiety;

each R* and R″ is a hydrocarbyl group having from 1 to 20 carbon atoms and may the same or different;

p is 0, 1, 2, 3, or 4;

q is 1, 2, 3, or 4;

R A is a structural bridge between the Cp moieties imparting stereorigidity to the metallocene compound;

M 5 is a group 4, 5, or 6 metal;

Q is a hydrocarbyl radical having 1 to 20 carbon atoms or is a halogen;

r is s minus 2, where s is the valence of M 5 ;

wherein (CpR* q ) has bilateral or pseudobilateral symmetry; R*q is selected such that (CpR* q ) forms a fluorenyl, alkyl substituted indenyl, or tetra-, tri-, or dialkyl substituted cyclopentadienyl radical; and (CpR″ p ) contains a bulky group in one and only one of the distal positions;

wherein the bulky group is of the formula AR W V ; and

where A is chosen from group 4 metals, oxygen, or nitrogen, and R W is a methyl radical or phenyl radical, and v is the valence of A minus 1.

11. The catalyst system of claim 1 , wherein the polypropylene matrix has a porosity of from 20% up to 85%, and a volume average median pore diameter of greater than 6 and less than 160 μm.

12. A process, comprising:

supporting an activator for a single site precursor compound on a support, the support having an average particle size of more than 30 μm up to 200 μm, a specific surface area of 400 m 2 /g or more, a pore volume of from 0.5 to 2 mL/g, and a mean pore diameter of from 1 to 20 nm (10 to 200 Å); and the support comprising agglomerates of a plurality of primary particles wherein the primary particles have an average particle size from 1 nm to 50 μm;

contacting the activator and a single site catalyst precursor compound to form a supported catalyst system having an average particle size of more than 30 μm up to 200 μm;

contacting the supported catalyst system with propylene under polymerization conditions to form a matrix of porous propylene polymer comprising at least 50 mol % propylene to form a polypropylene matrix having a porosity of at least 15%, and a volume average median pore diameter of less than 165 μm, as determined by mercury intrusion porosimetry; where active catalyst sites are distributed in the matrix.

13. The process of claim 12 , wherein the support comprises agglomerates of a plurality of primary particles having an average size from 1 nm to 30 μm.

14. The process of claim 12 , wherein the supported activator is essentially free of fines.

15. The process of claim 12 , wherein the support comprises spray dried silica having an average particle size of more than 50 μm, a specific surface area less than 1000 m2/g, or a combination thereof.

16. The process of claim 12 , wherein the specific surface area is more than 650 m2/g, the mean pore diameter is less than 7 nm (70 Å), the activator comprises alumoxane, and the supporting comprises contacting the activator and the support at a temperature of 40° C. or below.

17. The process of claim 12 , wherein the specific surface area is less than 650 m2/g or the mean pore diameter is greater than 7 nm (70 Å), or both, the activator comprises alumoxane, and the supporting comprises contacting the activator and the support at a temperature from −60 to 130° C.

18. The process of claim 12 , further comprising contacting the support with a co-activator selected from the group consisting of: trialkylaluminum, dialkylmagnesium, alkylmagnesium halide, and dialkylzinc.

19. The process of claim 12 , wherein the single site catalyst precursor compound is selected from precursor compounds I and II;

wherein precursor compound I is represented by the following formula:

(Cp) m R A n M 4 Q k

wherein:

each Cp is a cyclopentadienyl moiety or a substituted cyclopentadienyl moiety substituted by one or more hydrocarbyl radicals having from 1 to 20 carbon atoms;

R A is a structural bridge between two Cp moieties;

M 4 is a transition metal selected from groups 4 or 5;

Q is a hydride or a hydrocarbyl group having from 1 to 20 carbon atoms or an alkenyl group having from 2 to 20 carbon atoms, or a halogen;

m is 1, 2, or 3, with the proviso that if m is 2 or 3, each Cp may be the same or different;

n is 0 or 1, with the proviso that n=0 if m=1; and

k is such that k+m is equal to the oxidation state of M 4 , with the proviso that if k is greater than 1, each Q may be the same or different; and

wherein precursor compound II is represented by the following formula:

R A (CpR″ p )(CpR* q )M 5 Q r

wherein:

each Cp is a cyclopentadienyl moiety or substituted cyclopentadienyl moiety;

each R* and R″ is a hydrocarbyl group having from 1 to 20 carbon atoms and may the same or different;

p is 0, 1, 2, 3, or 4;

q is 1, 2, 3, or 4;

R A is a structural bridge between the Cp moieties imparting stereorigidity to the metallocene compound;

M 5 is a group 4, 5, or 6 metal;

Q is a hydrocarbyl radical having 1 to 20 carbon atoms or is a halogen;

r is s minus 2, where s is the valence of M 5 ;

wherein (CpR* q ) has bilateral or pseudobilateral symmetry; R* q is selected such that (CpR* q ) forms a fluorenyl, alkyl substituted indenyl, or tetra-, tri-, or dialkyl substituted cyclopentadienyl radical; and (CpR″ p ) contains a bulky group in one and only one of the distal positions;

wherein the bulky group is of the formula AR W V ; and

where A is chosen from group 4 metals, oxygen, or nitrogen, and R W is a methyl radical or phenyl radical, and v is the valence of A minus 1.

20. The process of claim 12 , wherein the single site catalyst precursor compound is represented by the formula:

wherein:

M is a group 4, 5, or 6 metal;

T is a bridging group;

each X is, independently, an anionic leaving group;

each R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , and R 13 is, independently, halogen atom, hydrogen, hydrocarbyl, substituted hydrocarbyl, halocarbyl, substituted halocarbyl, silylcarbyl, substituted silylcarbyl, germylcarbyl, substituted germylcarbyl substituent or a —NR′ 2 , —SR′, —OR, —OSiR′ 3 or —PR′ 2 radical, wherein R′ is one of a halogen atom, a C 1 -C 10 alkyl group, or a C 6 -C 10 aryl group.

21. The process of claim 20 , wherein at least one of R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , and R 13 is a cyclopropyl substituent represented by the formula:

wherein each R′ in the cyclopropyls substituent is, independently, hydrogen, a substituted hydrocarbyl group, an unsubstituted hydrocarbyl group, or a halogen.

22. The process of claim 20 , wherein:

M is selected from titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum and tungsten;

each X is independently selected from hydrogen, halogen, hydroxy, substituted or unsubstituted C 1 to C 10 alkyl groups, substituted or unsubstituted C 1 to C 10 alkoxy groups, substituted or unsubstituted C 6 to C 14 aryl groups, substituted or unsubstituted C 6 to C 14 aryloxy groups, substituted or unsubstituted C 2 to C 10 alkenyl groups, substituted or unsubstituted C 7 to C 40 arylalkyl groups, substituted or unsubstituted C 7 to C 40 alkylaryl groups and substituted or unsubstituted C 7 to C 40 arylalkenyl groups; or optionally are joined together to form a C 4 to C 40 alkanediyl group or a conjugated C 4 to C 40 diene ligand which is coordinated to M in a metallacyclopentene fashion; or optionally represent a conjugated diene, optionally, substituted with one or more groups independently selected from hydrocarbyl, trihydrocarbylsilyl, and trihydrocarbylsilylhydrocarbyl groups, said diene having a total of up to 40 atoms not counting hydrogen and forming a π complex with M;

each R 2 , R 4 , R 8 , and R 10 is independently selected from hydrogen, halogen, substituted or unsubstituted C 1 to C 10 alkyl groups, substituted or unsubstituted C 6 to C 14 aryl groups, substituted or unsubstituted C 2 to C 10 alkenyl groups, substituted or unsubstituted C 7 to C 40 arylalkyl groups, substituted or unsubstituted C 7 to C 40 alkylaryl groups, substituted or unsubstituted C 8 to C 40 arylalkenyl groups, and —NR′ 2 , —SR′, —OR′, —SiR′ 3 , —OSiR′ 3 , and —PR′ 2 radicals wherein each R′ is independently selected from halogen, substituted or unsubstituted C 1 to C 10 alkyl groups and substituted or unsubstituted C 6 to C 14 aryl groups;

R 3 , R 5 , R 6 , R 7 , R 9 , R 11 , R 12 , and R 13 are each selected from the group consisting of hydrogen, halogen, hydroxy, substituted or unsubstituted C 1 to C 10 alkyl groups, substituted or unsubstituted C 1 to C 10 alkoxy groups, substituted or unsubstituted C 6 to C 14 aryl groups, substituted or unsubstituted C 6 to C 14 aryloxy groups, substituted or unsubstituted C 2 to C 10 alkenyl groups, substituted or unsubstituted C 7 to C 40 arylalkyl groups, substituted or unsubstituted C 7 to C 40 alkylaryl groups and C 7 to C 40 substituted or unsubstituted arylalkenyl groups; and

T is selected from:

—B(R 14 )—, —Al(R 14 )—, —Ge—, —Sn—, —O—, —S—, —SO—, —SO 2 —, —N(R 14 )—, —CO—, —P(R 14 )—, and —P(O)(R 14 )—;

wherein R 14 , R 15 , and R 16 are each independently selected from hydrogen, halogen, C 1 to C 20 alkyl groups, C 6 to C 30 aryl groups, C 1 to C 20 alkoxy groups, C 2 to C 20 alkenyl groups, C 7 to C 40 arylalkyl groups, C 8 to C 40 arylalkenyl groups and C 7 to C 40 alkylaryl groups, optionally R 14 and R 15 , together with the atom(s) connecting them, form a ring; or

T is represented by the formula:

wherein R 17 , R 18 , R 19 , R 20 , R 21 , R 22 , R 23 , and R 24 are each independently selected from hydrogen, halogen, hydroxy, substituted or unsubstituted C 1 to C 10 alkyl groups, substituted or unsubstituted C 1 to C 10 alkoxy groups, substituted or unsubstituted C 6 to C 14 aryl groups, substituted or unsubstituted C 6 to C 14 aryloxy groups, substituted or unsubstituted C 2 to C 10 alkenyl groups, substituted or unsubstituted C 7 to C 40 alkylaryl groups, substituted or unsubstituted C 7 to C 40 alkylaryl groups and substituted or unsubstituted C 8 to C 40 arylalkenyl groups; optionally two or more adjacent radicals R 17 , R 18 , R 19 , R 20 , R 21 , R 22 , R 23 , and R 24 , including R 20 and R 21 , together with the atoms connecting them, form one or more rings; and

M 2 represents one or more carbon atoms, or a silicon, germanium, or tin atom.

23. A process, comprising:

(a) contacting a single site catalyst precursor compound, an activator and a support, the support comprising fractured agglomerates and having an average particle size of more than 30 μm up to 200 μm, a specific surface area of 400 m 2 /g or more, a pore volume of from 0.5 to 2 mL/g, and a mean pore diameter of from 1 to 20 nm (10 to 200 Å), to form a supported catalyst system;

(b) contacting the supported catalyst system and propylene monomer under polymerization conditions to form a matrix of porous propylene polymer comprising at least 50 mol % propylene and a mean pore diameter less than 165 μm as determined by mercury intrusion porosimetry; and

(c) dispersing active catalyst system sites within the matrix.

24. The process of claim 23 , further comprising (d) contacting the dispersed active catalyst system sites from (c) with one or more alpha-olefin monomers under polymerization conditions.

25. The catalyst system of claim 1 , wherein the support material has a specific surface area of less than 650 m 2 /g and a mean pore diameter of more than 7 nm (70 Å).

26. The catalyst system of claim 1 , wherein the support material has a specific surface area of less than 650 m 2 /g.

27. The catalyst system of claim 1 , wherein the support material further comprises an optional second or co-support material.

28. The catalyst system of claim 1 , where the support:

a) has an average particle size, PS, and/or a PS mode of 30 to 200 μm;

b) has a pore volume, PV, from 0.5 to 2 mL/g;

c) has a specific surface area, SA, of 400 to 1000 m 2 /g;

d) has a mean pore diameter, PD, of 1 to 7 nm;

e) comprises agglomerates composed of a plurality of primary particles having an average PS of 1 nm to less than 50 μm;

f) comprises microencapsulated agglomerates;

g) is spray dried; and

h) comprises amorphous silica and/or silica having a hydrated surface.

29. The catalyst system of claim 1 , where the single site catalyst precursor compound comprises one or more of: dimethylsilylene-bis(2-cyclopropyl-4-phenylindenyl)zirconium dichloride; dimethylsilylene-bis(2-cyclopropyl-4-phenylindenyl)hafnium dichloride; dimethylsilylene-bis(2-methyl-4-phenylindenyl)zirconium dichloride; dimethylsilylene-bis(2-methyl-4-phenylindenyl)hafnium dichloride; dimethylsilylene-bis(2-methyl-4-orthobiphenylindenyl)hafnium dichloride; dimethylsilylene-bis(2-methyl-4-orthobiphenylindenyl)zirconium dichloride; dimethylsilylene-(2-cyclopropyl-4-orthobiphenylindenyl)(2-methyl-4-3′,5′-di-t-butylphenylindenyl)hafnium dichloride; dimethylsilylene-(2-cyclopropyl-4-orthobiphenylindenyl)(2-methyl-4-3′,5′-di-t-butylphenylindenyl)zirconium dichloride; dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl) (2-methyl-4-phenyl indenyl) zirconium dichloride; dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl) (2-methyl-4-phenyl indenyl) hafnium dichloride; dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl) (2-methyl, 4-t-butylindenyl) zirconium dichloride; dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl) (2-methyl, 4-t-butylindenyl) hafnium dichloride; dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl) (2-methyl-4-phenylindacenyl) zirconium dichloride; dimethylsilylene-(2-isopropyl-4(4-t-butyl)phenyl)indenyl) (2-methyl-4-phenylindacenyl) hafnium dichloride; dimethylsilylene (4-o-Biphenyl-2-(1-methylcyclohexyl)methyl-indenyl) (4-(3,5-di-tert-butylphenyl)-2-methyl-indenyl) zirconium dichloride; and dimethylsilylene (4-o-Biphenyl-2-(1-methylcyclohexyl)methyl-indenyl) (4-(3,5-di-tert-butylphenyl)-2-methyl-indenyl) hafnium dichloride; where, in alternate embodiments, the dichloride in any of the compounds listed above may be replaced with dialkyl, dialkaryl, diflouride, diiodide, or dibromide, or a combination thereof.

30. The catalyst system of claim 1 , where the single site catalyst precursor compound is represented by the formula:

wherein:

M is a group 4, 5, or 6 metal;

T is a bridging group;

each X is, independently, an anionic leaving group;

each R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , and R 13 is, independently, halogen atom, hydrogen, hydrocarbyl, substituted hydrocarbyl, halocarbyl, substituted halocarbyl, silylcarbyl, substituted silylcarbyl, germylcarbyl, substituted germylcarbyl substituent or a —NR′ 2 , —SR′, —OR, —OSiR′ 3 or —PR′ 2 radical, wherein R′ is one of a halogen atom, a C 1 -C 10 alkyl group, or a C 6 -C 10 aryl group.

31. The catalyst system of claim 30 , wherein at least one of R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , and R 13 is a cyclopropyl substituent represented by the formula:

wherein each R′ in the cyclopropyls substituent is, independently, hydrogen, a substituted hydrocarbyl group, an unsubstituted hydrocarbyl group, or a halogen.

32. The process of claim 30 , wherein:

M is selected from titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum and tungsten;

each X is independently selected from hydrogen, halogen, hydroxy, substituted or unsubstituted C 1 to C 10 alkyl groups, substituted or unsubstituted C 1 to C 10 alkoxy groups, substituted or unsubstituted C 6 to C 14 aryl groups, substituted or unsubstituted C 6 to C 14 aryloxy groups, substituted or unsubstituted C 2 to C 10 alkenyl groups, substituted or unsubstituted C 7 to C 40 arylalkyl groups, substituted or unsubstituted C 7 to C 40 alkylaryl groups and substituted or unsubstituted C 7 to C 40 arylalkenyl groups; or optionally are joined together to form a C 4 to C 40 alkanediyl group or a conjugated C 4 to C 40 diene ligand which is coordinated to M in a metallacyclopentene fashion; or optionally represent a conjugated diene, optionally, substituted with one or more groups independently selected from hydrocarbyl, trihydrocarbylsilyl, and trihydrocarbylsilylhydrocarbyl groups, said diene having a total of up to 40 atoms not counting hydrogen and forming a π complex with M;

each R 2 , R 4 , R 8 , and R 10 is independently selected from hydrogen, halogen, substituted or unsubstituted C 1 to C 10 alkyl groups, substituted or unsubstituted C 6 to C 14 aryl groups, substituted or unsubstituted C 2 to C 10 alkenyl groups, substituted or unsubstituted C 7 to C 40 arylalkyl groups, substituted or unsubstituted C 7 to C 40 alkylaryl groups, substituted or unsubstituted C 8 to C 40 arylalkenyl groups, and —NR′ 2 , —SR′, —OR′, —SiR′ 3 , —OSiR′ 3 , and —PR′ 2 radicals wherein each R′ is independently selected from halogen, substituted or unsubstituted C 1 to C 10 alkyl groups and substituted or unsubstituted C 6 to C 14 aryl groups;

R 3 , R 5 , R 6 , R 7 , R 9 , R 11 , R 12 , and R 13 are each selected from the group consisting of hydrogen, halogen, hydroxy, substituted or unsubstituted C 1 to C 10 alkyl groups, substituted or unsubstituted C 1 to C 10 alkoxy groups, substituted or unsubstituted C 6 to C 14 aryl groups, substituted or unsubstituted C 6 to C 14 aryloxy groups, substituted or unsubstituted C 2 to C 10 alkenyl groups, substituted or unsubstituted C 7 to C 40 arylalkyl groups, substituted or unsubstituted C 7 to C 40 alkylaryl groups and C 7 to C 40 substituted or unsubstituted arylalkenyl groups; and

T is selected from:

—B(R 14 )—, —Al(R 14 )—, —Ge—, —Sn—, —O—, —S—, —SO—, —SO 2 —, —N(R 14 )—, —CO—, —P(R 14 )—, and —P(O)(R 14 )—;

wherein R 14 , R 15 , and R 16 are each independently selected from hydrogen, halogen, C 1 to C 20 alkyl groups, C 6 to C 30 aryl groups, C 1 to C 20 alkoxy groups, C 2 to C 20 alkenyl groups, C 7 to C 40 arylalkyl groups, C 8 to C 40 arylalkenyl groups and C 7 to C 40 alkylaryl groups, optionally R 14 and R 15 , together with the atom(s) connecting them, form a ring; or

T is represented by the formula:

wherein R 17 , R 18 , R 19 , R 20 , R 21 , R 22 , R 23 , and R 24 are each independently selected from hydrogen, halogen, hydroxy, substituted or unsubstituted C 1 to C 10 alkyl groups, substituted or unsubstituted C 1 to C 10 alkoxy groups, substituted or unsubstituted C 6 to C 14 aryl groups, substituted or unsubstituted C 6 to C 14 aryloxy groups, substituted or unsubstituted C 2 to C 10 alkenyl groups, substituted or unsubstituted C 7 to C 40 alkylaryl groups, substituted or unsubstituted C 7 to C 40 alkylaryl groups and substituted or unsubstituted C 8 to C 40 arylalkenyl groups; optionally two or more adjacent radicals R 17 , R 18 , R 19 , R 20 , R 21 , R 22 , R 23 , and R 24 , including R 20 and R 21 , together with the atoms connecting them, form one or more rings; and

M 2 represents one or more carbon atoms, or a silicon, germanium, or tin atom.

33. The catalyst system of claim 1 , wherein the catalyst system further comprises primary particles disagglomerated from the agglomerates.

34. A single site catalyst system comprising:

(a) a single site catalyst precursor compound;

(b) an activator; and

(c) a support having an average particle size of more than 30 μm up to 200 μm, a specific surface area of 400 m 2 /g or more, a pore volume of from 0.5 to 2 mL/g, and a mean pore diameter of from 1 to 20 nm (10 to 200 Å), the support comprising fractured agglomerates of a plurality of primary particles.

35. The process of claim 12 , wherein the catalyst system further comprises primary particles disagglomerated from the agglomerates.

36. A single site catalyst system comprising active catalyst sites distributed in a polypropylene matrix having a porosity of at least 15%, and a volume average median pore diameter of less than 165 μm, as determined by mercury intrusion porosimetry; where the matrix is obtained by contacting propylene and optional comonomer with the combination of

(a) a single site catalyst precursor compound;

(b) an activator; and

(c) a support having an average particle size of more than 30 μm up to 200 μm, a specific surface area of 400 m 2 /g or more, a pore volume of from 0.5 to 2 mL/g, and a mean pore diameter of from 1 to 20 nm (10 to 200 Å), the support comprising agglomerates of a plurality of primary particles wherein the primary particles have an average particle size from 1 nm to 50 μm.

37. The single site catalyst system of claim 36 , prepared by a process, comprising:

(a) supporting an activator for a single site precursor compound on a support, the support having an average particle size (PS) of more than 30 μm up to 200 μm, a specific surface area (SA) of 400 m 2 /g or more, a pore volume (PV) of from 0.5 to 2 mL/g (alternately 0.5 to 1.5 mL/g), and a mean pore diameter (PD) of from 1 to 20 nm (10 to 200 Å);

(b) contacting the supported activator and a single site catalyst precursor compound to form a supported catalyst system;

(c) contacting the supported catalyst system and propylene monomer under polymerization conditions to form a matrix of porous propylene polymer comprising at least 50 mol % propylene and a mean PD less than 165 μm as determined by mercury intrusion porosimetry;

(d) dispersing active catalyst system sites within the matrix; and

(e) contacting the dispersed active catalyst system sites from (d) with one or more alpha-olefin monomers under polymerization conditions to form a heterophasic copolymer.