Patents by Inventor Anthony J. Castelluccio

Anthony J. Castelluccio has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20230058913
    Abstract: The present disclosure provides a process. In an embodiment, the process includes contacting ethylene and octene under polymerization conditions at a temperature greater than 125° C. with a catalyst system comprising (i) a first polymerization catalyst having the structure of Formula (III), a second polymerization catalyst having the structure of Formula (I), and (iii) a chain shuttling agent. The process includes forming an ethylene/octene multi-block copolymer having a normalized OOO triad content greater than 0.25. The present disclosure provides the resultant composition produced by the process. In an embodiment, the composition includes an ethylene/octene multi-block copolymer having a normalized OOO triad content greater than 0.25.
    Type: Application
    Filed: December 23, 2020
    Publication date: February 23, 2023
    Inventors: Stacy L. Pesek, Jeffrey C. Munro, Zhe Zhou, Andrew J. Young, Anthony J. Castelluccio, Thomas Wesley Karjala, Jr.
  • Patent number: 10392450
    Abstract: A process to form a block copolymer comprising two or more regions or segments of differentiated polymer composition or properties, including feeding a first mixture that includes a chain shuttling agent, a solvent, the one or more monomers, and optionally hydrogen into a first reactor or reactor zone, feeding a second mixture that includes at least one olefin polymerization catalyst and at least one cocatalyst into the first reactor or reactor zone, contacting the first mixture and the second mixture under polymerization conditions in the first reactor or reactor zone to form a reaction mixture that is characterized by the formation of polymer chains from the monomers, allowing polymerization to occur in the first reactor or reactor zone and/or a second reactor or reactor zone to form polymer chains that are differentiated from the polymer chains, such that the resultant polymer has two or more chemically or physically distinguishable blocks.
    Type: Grant
    Filed: March 22, 2016
    Date of Patent: August 27, 2019
    Assignee: Dow Global Technologies LLC
    Inventors: Thomas W. Karjala, Brandon Fails, Jacob Veldman, Curvel Hypolite, James B. Crim, Anthony J. Castelluccio, Ludovicus J C Sluijts, Pradeep Jain
  • Patent number: 10138362
    Abstract: The invention provides a composition comprising a first composition, comprising at least one ethylene-based polymer, and wherein the first composition comprises a MWCDI value greater than 0.9, and a melt index ratio I10/I2 that meets the following equation: I10/I2?7.0?1.2×log (I2). The invention also provides a process to form a composition comprising at least two ethylene-based polymers, said process comprising the following: polymerizing ethylene, and optionally at least one comonomer, in solution, in the presence of a catalyst system comprising a metal-ligand complex of Structure I, as described herein, to form a first ethylene-based polymer; and polymerizing ethylene, and optionally at least one comonomer, in the presence of a catalyst system comprising a Ziegler/Natta catalyst, to form a second ethylene-based polymer.
    Type: Grant
    Filed: June 26, 2015
    Date of Patent: November 27, 2018
    Assignee: Dow Global Technologies LLC
    Inventors: Jian Wang, Pradeep Jain, Mehmet Demirors, Douglas S. Ginger, Anthony J. Castelluccio, Mridula Kapur
  • Patent number: 9932425
    Abstract: Improved reaction processes comprise reacting a mixture to form a product comprising a metal alkyl, metal oxide, or mixture thereof and then passing said product to a post-reactor heat exchanger. The improvement comprises one or more of the following: (1) reacting said metal alkyl compound with an acid to produce a soluble metal ester; or (2) adding an ionic surfactant; or (3) adding a mixture comprising an antioxidant to the product under conditions sufficient to avoid formation of significant amounts of insoluble metal or metal compounds derived from said metal alkyl compound; or (4) purging said post-reactor heat exchanger with an inert gas under conditions to remove metal oxide from the post-reactor heat exchanger.
    Type: Grant
    Filed: December 15, 2014
    Date of Patent: April 3, 2018
    Assignee: Dow Global Technologies LLC
    Inventors: Anthony J. Castelluccio, Jeffrey J. Dean, Alec Y. Wang, Lindsey A. Clark, Pradeep Jain, Roger L. Kuhlman, Angela N. Taha, Larry S. Green, Gary R. Marchand, Sean W. Ewart, Jeffrey A. Sims, Chris E. Blaschke, Brandon Fails
  • Publication number: 20180086857
    Abstract: A process to form a block copolymer comprising two or more regions or segments of differentiated polymer composition or properties, including feeding a first mixture that includes a chain shuttling agent, a solvent, the one or more monomers, and optionally hydrogen into a first reactor or reactor zone, feeding a second mixture that includes at least one olefin polymerization catalyst and at least one cocatalyst into the first reactor or reactor zone, contacting the first mixture and the second mixture under polymerization conditions in the first reactor or reactor zone to form a reaction mixture that is characterized by the formation of polymer chains from the monomers, allowing polymerization to occur in the first reactor or reactor zone and/or a second reactor or reactor zone to form polymer chains that are differentiated from the polymer chains, such that the resultant polymer has two or more chemically or physically distinguishable blocks.
    Type: Application
    Filed: March 22, 2016
    Publication date: March 29, 2018
    Inventors: Thomas W. Karjala, Brandon Fails, Jacob Veldman, Curvel Hypolite, James B. Crim, Anthony J. Castelluccio, Ludovicus JC Sluijts, Pradeep Jain
  • Patent number: 9708418
    Abstract: A process for recycling solvent used in an ethylene-based polymerization comprising: passing a solvent stream which has been used in a first ethylene-based solvent polymerization reactor through an online purification bed to produce a recycle solvent stream, wherein the solvent stream prior to being passed through the online purification bed comprises solvent, ethylene, hydrogen, polymerization by-products and optionally comonomer; and passing the recycle solvent stream from the online purification bed to a second ethylene-based solvent polymerization reactor; wherein the second ethylene-based solvent polymerization reactor exhibits a catalyst efficiency dip of less than or equal to 20% for no longer than a forty-eight hour period following a swap of the online purification bed to a regenerated purification bed which contains an adsorbent having low reactivity to alkenes is provided.
    Type: Grant
    Filed: February 16, 2012
    Date of Patent: July 18, 2017
    Assignee: DOW GLOBAL TECHNOLOGIES LLC
    Inventors: Stacey Hyde, Anthony J. Castelluccio, Frederik E. Gemoets
  • Publication number: 20170081444
    Abstract: The invention provides a composition comprising a first composition, comprising at least one ethylene-based polymer, and wherein the first composition comprises a MWCDI value greater than 0.9, and a melt index ratio I10/I2 that meets the following equation: I10/I2?7.0?1.2×log (I2). The invention also provides a process to form a composition comprising at least two ethylene-based polymers, said process comprising the following: polymerizing ethylene, and optionally at least one comonomer, in solution, in the presence of a catalyst system comprising a metal-ligand complex of Structure I, as described herein, to form a first ethylene-based polymer; and polymerizing ethylene, and optionally at least one comonomer, in the presence of a catalyst system comprising a Ziegler/Natta catalyst, to form a second ethylene-based polymer.
    Type: Application
    Filed: June 26, 2015
    Publication date: March 23, 2017
    Inventors: Jian Wang, Pradeep Jain, Mehmet Demirors, Douglas S. Ginger, Anthony J. Castelluccio, Mridula Babli Kapur
  • Publication number: 20150112005
    Abstract: Improved reaction processes comprise reacting a mixture to form a product comprising a metal alkyl, metal oxide, or mixture thereof and then passing said product to a post-reactor heat exchanger. The improvement comprises one or more of the following: (1) reacting said metal alkyl compound with an acid to produce a soluble metal ester; or (2) adding an ionic surfactant; or (3) adding a mixture comprising an antioxidant to the product under conditions sufficient to avoid formation of significant amounts of insoluble metal or metal compounds derived from said metal alkyl compound; or (4) purging said post-reactor heat exchanger with an inert gas under conditions to remove metal oxide from the post-reactor heat exchanger.
    Type: Application
    Filed: December 15, 2014
    Publication date: April 23, 2015
    Inventors: Anthony J. Castelluccio, Jeffrey J. Dean, Alec Y. Wang, Lindsey A. Clark, Pradeep Jain, Roger L. Kuhlman, Angela N. Taha, Larry S. Green, Gary R. Marchand, Sean W. Ewart, Jeffrey A. Sims, Chris E. Blaschke, Brandon Fails
  • Patent number: 8933156
    Abstract: Improved reaction processes comprise reacting a mixture to form a product comprising a metal alkyl, metal oxide, or mixture thereof and then passing said product to a post-reactor heat exchanger. The improvement comprises one or more of the following: (1) reacting said metal alkyl compound with an acid to produce a soluble metal ester; or (2) adding an ionic surfactant; or (3) adding a mixture comprising an antioxidant to the product under conditions sufficient to avoid formation of significant amounts of insoluble metal or metal compounds derived from said metal alkyl compound; or (4) purging said post-reactor heat exchanger with an inert gas under conditions to remove metal oxide from the post-reactor heat exchanger.
    Type: Grant
    Filed: June 8, 2009
    Date of Patent: January 13, 2015
    Assignee: Dow Global Technologies LLC
    Inventors: Anthony J. Castelluccio, Jeffrey J. Dean, Alec Y. Wang, Lindsey A. Clark, Pradeep Jain, Roger L. Kuhlman, Angela N. Taha, Larry S. Green, Gary R. Marchand, Sean W. Ewart, Jeffrey A. Sims, Chris E. Blaschke, Brandon Fails
  • Publication number: 20130341567
    Abstract: A process for recycling solvent used in an ethylene-based polymerization comprising: passing a solvent stream which has been used in a first ethylene-based solvent polymerization reactor through an online purification bed to produce a recycle solvent stream, wherein the solvent stream prior to being passed through the online purification bed comprises solvent, ethylene, hydrogen, polymerization by-products and optionally comonomer; and passing the recycle solvent stream from the online purification bed to a second ethylene-based solvent polymerization reactor; wherein the second ethylene-based solvent polymerization reactor exhibits a catalyst efficiency dip of less than or equal to 20% for no longer than a forty-eight hour period following a swap of the online purification bed to a regenerated purification bed which contains an adsorbent having low reactivity to alkenes is provided.
    Type: Application
    Filed: February 16, 2012
    Publication date: December 26, 2013
    Applicant: Dow Global Technologies LLC
    Inventors: Stacey Hyde, Anthony J. Castelluccio, Frederik E. Gemoets
  • Patent number: 8475933
    Abstract: The present invention relates to compositions and processes of making and using interpolymers having a controlled molecular weight distribution. Multilayer films and film layers derived from novel ethylene/?-olefin interpolymers are also disclosed.
    Type: Grant
    Filed: March 20, 2012
    Date of Patent: July 2, 2013
    Assignee: Dow Global Technologies LLC
    Inventors: Rajen M. Patel, David W. Fuchs, Pradeep Jain, Seema Karande, Mehmet Demirors, Mark Grant Spencer, Kim L. Walton, Angela N. Taha, Phillip D. Hustad, Roger L. Kuhlman, Anthony J. Castelluccio
  • Publication number: 20120231287
    Abstract: The present invention relates to compositions and processes of making and using interpolymers having a controlled molecular weight distribution. Multilayer films and film layers derived from novel ethylene/?-olefin interpolymers are also disclosed.
    Type: Application
    Filed: March 20, 2012
    Publication date: September 13, 2012
    Inventors: Rajen M. Patel, David W. Fuchs, Pradeep Jain, Seema Karande, Mehmet Demirors, Mark Grant Spencer, Kim L. Walton, Angela N. Taha, Phillip D. Hustad, Roger L. Kuhlman, Anthony J. Castelluccio
  • Patent number: 8153243
    Abstract: The present invention relates to compositions and processes of making and using interpolymers having a controlled molecular weight distribution. Multilayer films and film layers derived from novel ethylene/?-olefin interpolymers are also disclosed.
    Type: Grant
    Filed: June 13, 2007
    Date of Patent: April 10, 2012
    Assignee: Dow Global Technologies LLC
    Inventors: Rajen M. Patel, David W. Fuchs, Pradeep Jain, Seema Karande, Mehmet Demirors, Mark Grant Spencer, Kim L. Walton, Angela N. Taha, Phillip D. Hustad, Roger L. Kuhlman, Anthony J. Castelluccio
  • Publication number: 20110086963
    Abstract: Improved reaction processes comprise reacting a mixture to form a product comprising a metal alkyl, metal oxide, or mixture thereof and then passing said product to a post-reactor heat exchanger. The improvement comprises one or more of the following: (1) reacting said metal alkyl compound with an acid to produce a soluble metal ester; or (2) adding an ionic surfactant; or (3) adding a mixture comprising an antioxidant to the product under conditions sufficient to avoid formation of significant amounts of insoluble metal or metal compounds derived from said metal alkyl compound; or (4) purging said post-reactor heat exchanger with an inert gas under conditions to remove metal oxide from the post-reactor heat exchanger.
    Type: Application
    Filed: June 8, 2009
    Publication date: April 14, 2011
    Inventors: Anthony J. Castelluccio, Jeffrey J. Dean, Alec Y. Wang, Lindsey A. Clark, Pradeep Jain, Roger L. Kuhlman, Angela N. Taha, Larry S. Green, Gary R. Marchand, Sean W. Ewart, Jeffrey A. Sims, Chris E. Blaschke, Brandon Fails