Abstract: The present invention relates to fractional melt flow rate powders wherein the particles are substantially spherical in shape and range in size from about 10 up to about 200 microns. The invention also relates to a process whereby a dispersible olefin copolymer resin can be converted into a microfine powder with reduced melt index. The process entails dispersing a molten olefin copolymer resin containing silane functionality in a liquid medium in the presence of a nonionic surfactant and catalyst and, after the melt flow rate is reduced to the desired level, cooling the dispersion to below the melt point of the olefin polymer.

Abstract: A method for pretreatment of a palladium-gold catalyst useful in the synthesis of vinyl acetate. A virgin catalyst, following reduction to the metallic palladium and gold, is first heated at elevated temperatures in the presence of an oxidizing agent such as air. The oxidizing agent is withdrawn and an inert gas such as nitrogen is introduced. The catalyst is heated again at a temperature up to 500.degree. C. in the presence of a reducing agent such as hydrogen or ethylene. Improvements in selectivity and yield are obtained.

Abstract: Improved two-component blends which exhibit good adhesion to 4-methylpentene-1 polymers and vinyl alcohol polymers and which may be used as an adhesive interlayer when laminating layers of the polymers are provided. Ethylene-alkyl acrylate copolymers, preferably ethylene n-butyl acrylate copolymers, and modified propylene polymers, preferably maleic anhydride grafted statistical propylene-ethylene copolymers and propylene-ethylene impact copolymers, are combined to obtain the blends of the invention. Useful laminated structures comprised of a layer of poly-4-methylpentene-1 homopolymer or copolymer, a layer of the adhesive blend and a layer of ethylene-vinyl alcohol copolymer with one or more optional layers, such as a paperboard, are also disclosed.

Abstract: The present invention is directed to a novel halosilane cocatalyst component which may be used in conjunction with an aluminum-containing cocatalyst to provide enhanced catalytic activity of a vanadium based solid catalyst component in the polymerization of .alpha.-olefins. In addition to the enhancement in the catalytic activity obtaining using the present catalyst system, the resultant polymer produced by the present invention exhibits improved physical properties compared with polymers produced by prior art vanadium based catalyst systems. Thus, the catalyst system of the instant invention represents an advance in the art in view of the combination of increased catalytic activity, i.e. yield of polymer produced, and enhanced physical properties of the polyolefin produced.In accordance with the present invention, a catalyst system is provided which comprises a solid catalyst component and a halosilane cocatalyst component.

Abstract: A bimodal silica gel particle, its method of preparation and its use as a catalyst support in the polymerization of olefins is disclosed. The bimodal silica gel particle exhibits a bimodal pore radius distribution, wherein the silica gel particle has a first average pore radius and a second average pore radius differing by at least about 20 .ANG.. The bimodal silica gel particle is useful as a support for a transition metal-based catalyst to provide a polyolefin having a broad or bimodal molecular weight distribution.

Abstract: A highly energy efficient process for removing hydrocarbons from polymer slurries is disclosed. The process includes feeding a hydrocarbon-containing polymer slurry to a flash tank to flash a portion of the hydrocarbon from the slurry. Thereafter, the resulting slurry is fed to a fluid bed dryer wherein additional hydrocarbon is stripped from the polymer. Subsequently, the resulting polymer powder is transferred to a powder silo wherein further hydrocarbon is removed from the polymer utilizing a heated purge gas flowing countercurrent to the polymer powder. The polymer output preferably has a low hydrocarbon content, on the order of 100 ppm or less.

Abstract: Tough, puncture- and tear-resistant films having a high degree of flexibility and softness are provided. The monolayer and multilayer films of the invention are obtained using copolymers of propylene with 8 to 40 weight percent ethylene produced by gas phase polymerization of the monomers in dual reactors. The films will have a 1% secant modulus from 5,000 psi to 70,000 psi. Melting points of these films are higher than that of low density polyethylene and, most generally, in the range 125.degree. C. to 160.degree. C.

Abstract: Improved filled silane copolymer compositions resistant to premature crosslinking during compounding and storage but which are readily hydrolyzed and undergo cure in the presence of silanol condensation catalyst are provided. The compositions are comprised of random copolymers of ethylene and vinyltriethoxysilane and contain relatively high levels of particulate fillers. Rubbery ethylene copolymers are included with the silane copolymer to produce compositions with superior physical properties. The invention also relates to the method of crosslinking these compositions by combining the filled silane copolymer compositions with a second component which has a silanol condensation catalyst dispersed in a polymer resin.

Abstract: Mixed catalyst compositions comprised of a first supported chromium-containing catalyst component and a second supported chromium-containing catalyst component and which additionally have one or more metallic or non-metallic catalytic agents associated therewith are provided. The additional metallic or non-metallic elements associated with the catalyst components can be aluminum, titanium, zirconium, boron, phosphorous or combinations thereof. The pore volume of the silica supports used for the first and second catalyst components differs by at least 0.3 cc/g. The mixed catalyst compositions of the invention are useful for the preparation of polyolefins. They are particularly useful of polymerization of ethylene in particle form polymerizations to produce high density polyethylene blow molding resins having good processability and physical properties. The improved particle form polymerization process and products obtained thereby using the above-described mixed catalyst compositions are also described.

Abstract: A process for preparing an ethylene-unsaturated polycarboxylic graft copolymer is disclosed. In this process an ethylene polymer having terminal double bond functionality is contacted with an unsaturated polycarboxylic compound in the presence of a catalytically effective amount of an organic peroxide.

Abstract: Adhesives comprising carboxylic acid- or anhydride-grafted elastomeric polyester copolymers, and composite structures made therefrom, are disclosed.

Abstract: Modified ethylene/n-butyl acrylate copolymers obtained by grafting a half-ester of maleic acid onto a randomly copolymerized ethylene/n-butyl acrylate backbone are provided. The carboxylic functionalized polymers of the invention exhibit superior adhesion to non-polar substrates. They are particularly effective for adhering metals.

Abstract: A method of using a catalyst with a suitable cocatalyst in the polymerization or copolymerization of 1-olefins are disclosed. The catalyst is prepared by: a) contacting a Group IIA organometallic compound, like 2-methylpentanoxymagnesium chloride, or a Group III organometallic compound, like triethylaluminum, or a combination thereof, with a porous or nonporous biodegradable substrate having active surface hydroxyl groups, like cellulose, to provide a modified biodegradable substrate; then b) contacting the modified biodegradable substrate with a transition metal compound, such as a transition metal halide or alkoxide, like titanium tetrachloride or vanadium (V) trichloride oxide, to form discrete catalyst particles. The catalyst particles are used in conjunction with a suitable cocatalyst, like triethylaluminum, in the homopolymerization or copolymerization of 1-olefins. During polymerization, porous biodegradable catalyst particles are fragmented into small solid particles that are trapped within polymer.

Abstract: A closed tube extension or deadleg is included below the vertical tube of a hydrocarbon pyrolysis furnace. The deadleg passively collects spall coke particles to avoid plugging of the tube or its hydrocarbon inlet. Inspection or cleaning devices can be inserted through the deadleg into the tube and blocked tubes can be cleared. Pressurized steam and/or air can be injected through the deadleg to accelerate decoking of individual tubes.

Abstract: A novel catalyst support and a method for preparation thereof, characterized by the presence of selected amounts of a hydrocarbon soluble magnesium-containing compound applied to the support relative to solvent, wherein a surface uniformly and essentially continuously moistened with the solvated magnesium compound in a condition of incipient precipitation to permit the formation of a regular essentially continuous distribution of the magnesium compound onto and conforming to the support material. The drying process under these conditions is effective in maintaining to a high degree the effective surface area and pore volume of the material. The support containing the adsorbed magnesium is then dried in a controlled manner to essential incipient wetness conditions providing a regular spatial distribution of stacked reticular magnesium values at a level of one to five molecular monolayers on the support.

Abstract: A process for making a biodegradable aliphatic polyester and the polyester so formed is disclosed. The process comprises copolymerizing a cyclic ketene acetal having the structural formula ##STR1## where R is a bivalent moiety, and an olefin. This copolymerization occurs in a solution of a tertiary alcohol and in the presence of a free radical initiating effective amount of a compound having the structural formula ##STR2## where R.sup.1, R.sup.2, R.sup.3, R.sup.4, R.sup.5 and R.sup.6 are the same or different and are C.sub.1 -C.sub.20 hydrocarbyl, C.sub.1 -C.sub.20 hydrocarbyloxy, cyano, halogen, carboxy, carboalkoxy, carbonyl or formyl. The copolymerization occurs at a temperature in the range of between in excess of ambient temperature and less than 100.degree. C. and at a pressure in excess of about 2,000 psi.

Abstract: Filled, pelletized silane copolymer compositions resistant to premature crosslinking during compounding and storage but which are readily hydrolyzed and undergo cure in the presence of silanol condensation catalyst are provided. The compositions comprise random copolymers of ethylene an vinyltriethoxysilane with relatively high levels of particulate fillers, such as carbon black, alumina trihydrate and the like, dispersed therein. The invention also relates to a method of crosslinking these compositions by combining the filled silane copolymer composition with a second component containing a silanol condensation.

Abstract: The present invention relates to improved polymeric compositions based on ethylene-vinyl ester and ethylene-alkyl acrylate copolymers which can be crosslinked to provide insulation coatings for wire and cable products. The copolymer compositions contain a hydrated inorganic filler, an alkoxysilane, an antioxidant and a polymeric processing additive. Organic peroxides are preferably employed to facilitate crosslinking. An improved method for providing the improved compositions and electrical conductors coated with the crosslinkable polymeric compositions are also provided by the invention.

Abstract: The present invention relates to improved flame retardant insulation/jacketing compositions for wire and cable products based on ethylene-vinyl ester and ethylene-alkyl acrylate copolymers. The copolymers are formulated with a hydrated inorganic filler, an alkoxysilane, a crosslinking agent, a processing additive and a combination of specific antioxidants, namely, a pentaerythritol betaalkylthiopropionate and a hindered phenol. The formulations stabilized with the pentaerythritol betaalkylthiopropionate/hindered phenol combination have good heat stability and do not tarnish or discolor the surface of the copper conductor upon steam vulcanization.

Abstract: The present invention is directed to improved microfine propylene polymer powders having reduced fines which are comprised of spherical or substantially spherical particles and have a number average particle size from about 25 to about 60. A process for preparing the improved powders is also provided. The process involves dispersing a molten propylene homopolymer or copolymer which has been visbroken in a liquid medium in the presence of a nonionic surfactant, cooling the dispersion below the melt point of the propylene polymer and recovering the powder.