Exxon Research and Engineering Company

Exxon Chemical Patents, Inc.

Terrence Huff

James J McAlpin

Burnett H Johnson

Edward N Kresge

Bradley P Etherton

Eugene E Poirot

Arthur W Langer, Jr

Harry J Wristers

James John Mcalpin

James C Randall, Jr

A thermoplastic polymer composition incorporating at least about 50 wt % polypropylene, at least about 20 wt % of an elastomer such as EP rubber and at least about 4 wt % plastomer. The plastomer is preferably a single site catalyzed ethylene based copolymer having a density less than about 0.915. By adjusting the amount of the plastomer in the composition, considerable control is secured over post-mold shrinkage of components produced through injection molding operations utilizing the composition. The composition can be prepared as a reactor blend or a melt blend. The composition is particularly useful in producing large components such as bumpers and exterior trim fascia for automobiles.

Thermoplastic polymer compositions and their production and use

Disclosed are unsaturated .alpha.-olefin/.alpha., .omega.-diene copolymers, and a method of preparation thereof. The copolymers are generally crystalline, free of gel and cross-links, and contain unsaturated side chains and long chain branching. The copolymers contain up to 5 mole percent diene incorporated therein, and may be prepared by copolymerization using a solid-phase, insoluble coordination catalyst, without a solvent, and below the crystalline melting point of the copolymer.

Method for preparation of unsaturated alpha-olefin copolymers

Disclosed are unsaturated .alpha.-olefin/.alpha.,.omega.-diene copolymers, and a method of preparation thereof. The copolymers are generally crystalline, free of gel and cross-links, and contain unsaturated side chains and long chain branching. The copolymers contain up to 5 mole percent diene incorporated therein, and may be prepared by copolymerization using a solid-phase, insoluble coordination catalyst, without a solvent, and below the crystalline melting point of the copolymer.

Unsaturated propylene/.alpha., .omega.-diene copolymers

A thermoplastic olefin comprising an alloy of an olefin copolymer elastomer and a propylene/comonomer random copolymer is provided. The comonomer is selected from one or more of ethylene and C.sub.4 to C.sub.10 alpha-olefins. Polypropylene is an optional component of the alloy. The alloy may be produced by melt blending, reactor blending or a combination thereof, of the various components.

Thermoplastic olefin alloys and method for producing the same

Impact-modified polymeric materials are produced by visbreaking certain reactor blends. In a preferred embodiment, impact-modified polypropylene materials are produced by visbreaking a reactor blend of polypropylene and thermoplastic polyethylene. The polypropylene material is preferably homopolypropylene having a melt flow rate of less than about 1 dg/min. Such impact-modified polymeric materials manifest unexpected compatibility characteristics, increased impact resistance at low temperatures, improved antiblush characteristics and improved flow characteristics.

Impact-modified polymers (p-1304)

An aromatic hydrocarbon modified soluble mixed aluminum hydrocarbyl-Lewis base co-catalyst composition comprising (i) at least two different classes of aluminum hydrocarbyls the first being an aluminum hydrocarbyl halide, the second being an aluminum hydrocarbyl hydride and/or aluminum trialkyl and (ii) at least one Lewis base represented by the formula: ##STR1## wherein each Y can be --OR', --NR.sub.2 and R' with the proviso that at least two be --OR' or --NR.sub.2, Z is an alkylene radical forming a 5 or 6 membered ring with the carbonyldioxy group or Z is alkyl substituted alkylene group wherein the alkyl radical can have from 1 to 8 carbon atoms, R is an aryl, allyl or alkyl group having from 1 to 20 carbon atoms and R' is an alkyl, cycloalkyl, aryl or aralkyl radical having from 1 to 20 carbon atoms. The co-catalyst is employed with a titanium halide catalyst for the polymerization of olefins to obtain a advantageous balance of catalytic activity and polymer product stereoregularity.

High efficiency polymerization catalyst component for use in the

A aliphatic hydrocarbon soluble mixed aluminum hydrocarbyl-Lewis base co-catalyst composition comprising (i) at least two different classes of aluminum hydrocarbyls the first being an aluminum hydrocarbyl halide, the second being an aluminum hydrocarbyl hydride and/or aluminum trialkyl and (ii) at least one Lewis base represented by the formula: ##STR1## wherein each Y can be -OR', -NR.sub.2 ' and R' with the proviso that at least two be -OR' or -NR.sub.2 ', Z is an alkylene radical forming a 5 or 6 membered ring with the carbonyldioxy group or Z is alkyl substituted alkylene group wherein the alkyl radical can have from 1 to 8 carbon atoms, R is an aryl, allyl or alkyl group having 1 to 20 carbon atoms and R' is an alkyl, cycloalkyl, aryl or aralkyl radical having from 1 to 20 carbon atoms. The co-catalyst is employed with a titanium halide catalyst for the polymerization of olefins to obtain a advantageous balance of catalytic activity and polymer product stereoregularity.

Extremely strong, i.e., non-friable TiCl.sub.3 Ziegler-type polymerization catalyst are obtained by prepolymerizing a reduced solid TiCl.sub.3 product with a mixture of propylene and linear C.sub.8 -C.sub.18 alpha-olefin to produce a reduced solid TiCl.sub.3 product containing 5 to 35 weight percent of a copolymer of propylene and C.sub.8 -C.sub.18 alpha-olefin having a ratio of the infrared spectrum of the copolymer at 720 cm.sup.-1 : the infrared spectrum of the copolymer at 975 cm.sup.-1 in the range of 0.04 to 0.20.

Titanium trichloride catalyst component and the process for the

Melt mixed, melt-flowable blends of polypropylene, at least about 30% polyethylene and from about 4 to about 11% ethylene-propylene copolymer rubber, and method for making same, are disclosed. Such blends possess higher low temperature Izod and Gardner impact strength than conventional impact polypropylene blends, while having a comparable or higher flexural modulus.

High impact melt-flowable dual continuum melt mixed polymer blends of

Polyolefins are prepared wherein at least about ninety-five percent of the product is retained on a 100 mesh screen. The polymerization process involves contacting the alpha-olefin with a Ziegler catalyst system wherein the catalyst has been prepared by mixing the active catalytic particles with a fibrillatable polyolefin and a non-fibrillatable polyolefin followed by ballmilling the mixture for a period of time sufficient to cause a fibrous mat to form, entrapping the catalyst particles in the mat which is, in turn, carried by the non-fibrillatable polyolefin.

Preparing polyolefins with a narrow particle size distribution and

A cross-linked, melt-flowable thermoplastic elastomer blend of a monoolefin polymer rubber and cross-linkable low density polyethylene which are essentially fully cured in the presence of polypropylene is disclosed. The reprocessable blend has a much improved melt rheology and is useful for making flexible molded or extruded articles having an extremely good balance of mechanical properties, particularly high resiliency, tensile strength, flexural modulus, heat distortion resistance, low permanent set, and the like, without requiring vulcanization.

Cross-linked melt-flowable thermoplastic elastomer blend comprising EPR

An impact polypropylene blend having an excellent balance of overall mechanical properties, particularly high impact strength, and significantly improved optical properties, comprising about 2 to about 22% by weight of an ethylene-propylene copolymer elastomer and about 1 to about 15% by weight of a low density polyethylene which are at least partially cured in the presence of polypropylene. The high impact polypropylene blends containing about 70 to about 95% by weight polypropylene have surprisingly good optical properties and are useful for making molded or extruded high clarity articles, such as containers, films, and the like.

Polypropylene blends having high impact strength and improved optical

Novel high impact plastics are prepared by the inclusion of 2 to 30 weight percent of bromobutyl rubber in polymers of styrene and styrene-acrylonitrile and the grafting of said polymers onto said rubber. The graft copolymers are obtained by polymerizing the monomers of styrene or styrene-acrylonitrile in the presence of the bromobutyl rubber, which is preferably precrosslinked.

Bromobutyl rubber-styrene-acrylonitrile graft copolymers

A nonwoven mat of polyolefin fiber is contacted with a gaseous sulfur dioxide-chlorine mixture to sulfo-chlorinate the surface of the polyolefin fibers to a relatively high sulfur content and then preferably treated with an amine, either after compacting the mat or before compacting the mat to form a structure suitable as a battery separator. The mat can be used for other structures besides battery separators. And it can be separated into individually wettable staple fibers before compaction, i.e. individual separate fibers which are wettable.

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Baytown, TX, United States of America

Terrence Huff