Patents Assigned to Formosa Plastics Corporation, U.S.A.
  • Publication number: 20240084051
    Abstract: Disclosed are support-activators and catalyst compositions comprising the support-activators for polymerizing olefins in which the support-activator includes clay heteroadduct, prepare from a colloidal phyllosilicate such as a colloidal smectite clay, which is chemically-modified with a heterocoagulation agent. By limiting the amount of heterocoagulation reagent relative to the colloidal smectite clay as described herein, the smectite heteroadduct support-activator is a porous and amorphous solid which can be readily isolated from the resulting slurry by a conventional filtration process, and which can activate metallocenes and related catalysts toward olefin polymerization. Related compositions and processes are disclosed.
    Type: Application
    Filed: October 11, 2023
    Publication date: March 14, 2024
    Applicant: Formosa Plastics Corporation, U.S.A.
    Inventors: Michael D. Jensen, Kevin Chung, Daoyong Wang, Wei-Chun Shih, Guangxue Xu, Chih-Jian Chen, Charles R. Johnson, II, Mary Lou Cowen
  • Publication number: 20230399420
    Abstract: Disclosed are support-activators and catalyst compositions comprising the support-activators for polymerizing olefins in which the support-activator includes a clay heteroadduct, also termed a composite, prepared from a colloidal phyllosilicate such as a colloidal smectite clay, which is chemically-modified with a surfactant. In an aspect, the clay composite can comprise the contact product of a colloidal smectite clay and a surfactant in a liquid carrier, but in the absence of any other reactant such as a cationic polymetallate, and their use as support-activators for metallocene precatalysts is also described. The use of surfactants with cationic polymetallates in forming clay-composites is also described.
    Type: Application
    Filed: May 24, 2023
    Publication date: December 14, 2023
    Applicant: Formosa Plastics Corporation, U.S.A.
    Inventors: Kevin Chung, Michael D. Jensen, Yiqun Fang, Casey Zamzow, Charles R. Johnson, II, Mary Lou Cowen, Jenny Chun-Yu Chen
  • Patent number: 11814461
    Abstract: Disclosed are support-activators and catalyst compositions comprising the support-activators for polymerizing olefins in which the support-activator includes clay heteroadduct, prepare from a colloidal phyllosilicate such as a colloidal smectite clay, which is chemically-modified with a heterocoagulation agent. By limiting the amount of heterocoagulation reagent relative to the colloidal smectite clay as described herein, the smectite heteroadduct support-activator is a porous and amorphous solid which can be readily isolated from the resulting slurry by a conventional filtration process, and which can activate metallocenes and related catalysts toward olefin polymerization. Related compositions and processes are disclosed.
    Type: Grant
    Filed: March 15, 2023
    Date of Patent: November 14, 2023
    Assignee: FORMOSA PLASTICS CORPORATION, U.S.A.
    Inventors: Michael D Jensen, Kevin Chung, Daoyong Wang, Wei-Chun Shih, Guangxue Xu, Chih-Jian Chen, Charles R. Johnson, II, Mary Lou Cowen
  • Patent number: 11760851
    Abstract: A cast film, for use in monolayer and multilayer applications, having an outstanding inherent cling property is disclosed. Additionally, a multilayer cast film utilizing a cast film component layer prepared from a Ziegler-Natta catalyzed ethylene and alpha-olefin copolymer is disclosed, wherein the cast film component layer has a cling force of at least 200 grams-force per inch width at 200% pre-stretch, a slow puncture resistance of greater than 50 J/mm, and a TD tear strength of greater than 450 g/mil, with no cling additives present in the cast film component layer.
    Type: Grant
    Filed: June 30, 2014
    Date of Patent: September 19, 2023
    Assignee: Formosa Plastics Corporation, U.S.A.
    Inventors: Chih-Jian Chen, Honglan Lu, Guangxue Xu, Ming-Yung Lee, Raj Ranjan
  • Publication number: 20230242683
    Abstract: Disclosed are support-activators and catalyst compositions comprising the support-activators for polymerizing olefins in which the support-activator includes clay heteroadduct, prepare from a colloidal phyllosilicate such as a colloidal smectite clay, which is chemically-modified with a heterocoagulation agent. By limiting the amount of heterocoagulation reagent relative to the colloidal smectite clay as described herein, the smectite heteroadduct support-activator is a porous and amorphous solid which can be readily isolated from the resulting slurry by a conventional filtration process, and which can activate metallocenes and related catalysts toward olefin polymerization. Related compositions and processes are disclosed.
    Type: Application
    Filed: March 15, 2023
    Publication date: August 3, 2023
    Applicant: Formosa Plastics Corporation, U.S.A.
    Inventors: Michael D. Jensen, Kevin Chung, Daoyong Wang, Wei-Chun Shih, Guangxue Xu, Chih-Jian Chen, Charles R. Johnson, II, Mary Lou Cowen
  • Patent number: 11634513
    Abstract: Disclosed are support-activators and catalyst compositions comprising the support-activators for polymerizing olefins in which the support-activator includes clay heteroadduct, prepare from a colloidal phyllosilicate such as a colloidal smectite clay, which is chemically-modified with a heterocoagulation agent. By limiting the amount of heterocoagulation reagent relative to the colloidal smectite clay as described herein, the smectite heteroadduct support-activator is a porous and amorphous solid which can be readily isolated from the resulting slurry by a conventional filtration process, and which can activate metallocenes and related catalysts toward olefin polymerization. Related compositions and processes are disclosed.
    Type: Grant
    Filed: April 19, 2022
    Date of Patent: April 25, 2023
    Assignee: FORMOSA PLASTICS CORPORATION, U.S.A.
    Inventors: Michael D Jensen, Kevin Chung, Daoyong Wang, Wei-Chun Shih, Guangxue Xu, Chih-Jian Chen, Charles R. Johnson, II, Mary Lou Cowen
  • Patent number: 11572425
    Abstract: Cyclic organosilicon compounds having a structure represented by the general formula and a method for using thereof as a component of catalysts for producing propylene polymer having a very high melt-flowability are disclosed. The cyclic organosilicon compounds are employed as external electron donors in Ziegler-Natta catalyst systems to dramatically improve the hydrogen response, and therefore the catalyst systems can be used to prepare polymer having high melt-flowability and high isotacticity at high yield.
    Type: Grant
    Filed: May 15, 2020
    Date of Patent: February 7, 2023
    Assignee: Formosa Plastics Corporation, U.S.A.
    Inventors: Lei Zhang, Yiqun Fang
  • Patent number: 11492429
    Abstract: What is disclosed is a Ziegler-Natta catalyzed ethylene and alpha-olefin LLDPE copolymer having a unique composition distribution and long chain-branching. The polymers of the present invention inherently exhibit outstanding melt strength with great bubble stability, sufficient flexibility, excellent gel performance, as well as desirable mechanical properties such as balanced toughness and stiffness, which are desirable properties for thick gauge film applications. Specifically, the polymers of the present invention.
    Type: Grant
    Filed: June 5, 2020
    Date of Patent: November 8, 2022
    Assignee: Formosa Plastics Corporation, U.S.A.
    Inventors: Peng Li, Ming-Yung Lee, Tieqi Li, Honglan Lu
  • Publication number: 20220242976
    Abstract: Disclosed are support-activators and catalyst compositions comprising the support-activators for polymerizing olefins in which the support-activator includes clay heteroadduct, prepare from a colloidal phyllosilicate such as a colloidal smectite clay, which is chemically-modified with a heterocoagulation agent. By limiting the amount of heterocoagulation reagent relative to the colloidal smectite clay as described herein, the smectite heteroadduct support-activator is a porous and amorphous solid which can be readily isolated from the resulting slurry by a conventional filtration process, and which can activate metallocenes and related catalysts toward olefin polymerization. Related compositions and processes are disclosed.
    Type: Application
    Filed: April 19, 2022
    Publication date: August 4, 2022
    Applicant: Formosa Plastics Corporation, U.S.A.
    Inventors: Michael D Jensen, Kevin Chung, Daoyong Wang, Wei-Chun Shih, Guangxue Xu, Chih-Jian Chen, Charles R. Johnson, II, Mary Lou Cowen
  • Patent number: 11339229
    Abstract: Disclosed are support-activators and catalyst compositions comprising the support-activators for polymerizing olefins in which the support-activator includes clay heteroadduct, prepare from a colloidal phyllosilicate such as a colloidal smectite clay, which is chemically-modified with a heterocoagulation agent. By limiting the amount of heterocoagulation reagent relative to the colloidal smectite clay as described herein, the smectite heteroadduct support-activator is a porous and amorphous solid which can be readily isolated from the resulting slurry by a conventional filtration process, and which can activate metallocenes and related catalysts toward olefin polymerization. Related compositions and processes are disclosed.
    Type: Grant
    Filed: January 27, 2020
    Date of Patent: May 24, 2022
    Assignee: FORMOSA PLASTICS CORPORATION, U.S.A.
    Inventors: Michael D. Jensen, Kevin Chung, Daoyong Wang, Wei-Chun Shih, Guangxue Xu, Chih-Jian Chen, Charles R. Johnson, II, Mary Lou Cowen
  • Patent number: 11117995
    Abstract: The present invention relates to a polypropylene composition comprising a long chain branched polymer having high melt strength. The process for preparing the corresponding polypropylene having composition is provided comprising blending a propylene base polymer with a unsaturated polyfunctional poly(alkylsiloxane), a polyfunctional acrylate coagent, an initiator, additives such as stabilizer, acid neutralizer and antioxidants, and reactive extruding the blend to form a branched polymer composition bridged by siloxane units.
    Type: Grant
    Filed: August 23, 2018
    Date of Patent: September 14, 2021
    Assignee: Formosa Plastics Corporation, U.S.A.
    Inventors: Chaowei Feng, Ming-Yung Lee, Honglan Lu
  • Publication number: 20210230318
    Abstract: Disclosed are support-activators and catalyst compositions comprising the support-activators for polymerizing olefins in which the support-activator includes clay heteroadduct, prepare from a colloidal phyllosilicate such as a colloidal smectite clay, which is chemically-modified with a heterocoagulation agent. By limiting the amount of heterocoagulation reagent relative to the colloidal smectite clay as described herein, the smectite heteroadduct support-activator is a porous and amorphous solid which can be readily isolated from the resulting slurry by a conventional filtration process, and which can activate metallocenes and related catalysts toward olefin polymerization. Related compositions and processes are disclosed.
    Type: Application
    Filed: January 27, 2020
    Publication date: July 29, 2021
    Applicant: Formosa Plastics Corporation, U.S.A.
    Inventors: Michael D. Jensen, Kevin Chung, Daoyong Wang, Wei-Chun Shih, Guangxue Xu, Chih-Jian Chen, Charles R. Johnson, II, Mary Lou Cowen
  • Patent number: 10954324
    Abstract: What is disclosed is a method for preparing a catalyst system and a catalyst system for polymerizing or copolymerizing an ?-olefin. Catalyst component (A) is obtained by a process of reacting a magnesium complex (A-1) containing acid salts of group IB-VIIIB elements formed by contacting a magnesium halide with an acid salt solution of group IB-VIIIB metals or spherical particles adducts, an internal electron donor (A-2) of diester or diether or composite compounds, and a titanium compound (A-3). The catalyst compound (A) is contacted with a silicon compound (B) and an organoaluminium compound (C) to complete the catalyst system providing a good balance of catalyst performance in terms of activity and stereo-specificity.
    Type: Grant
    Filed: November 13, 2017
    Date of Patent: March 23, 2021
    Assignee: Formosa Plastics Corporation, U.S.A.
    Inventor: Demin Xu
  • Patent number: 10442874
    Abstract: Heterocyclic organic compounds are used as electron donors in conjunction with solid Ziegler-Natta type catalyst in processes in which polyolefins such as polypropylene are produced. The electron donors may be used in the preparation of solid catalyst system, thus serving as “internal electron donors,” or they may be employed during or prior to polymerization with the co-catalyst as “external electron donors.
    Type: Grant
    Filed: April 23, 2018
    Date of Patent: October 15, 2019
    Assignee: Formosa Plastics Corporation, U.S.A.
    Inventors: Yiqun Fang, Demin Xu, Ming-Yung Lee
  • Patent number: 9951152
    Abstract: Heterocyclic organic compounds are used as electron donors in conjunction with solid Ziegler-Natta type catalyst in processes in which polyolefins such as polypropylene are produced. The electron donors may be used in the preparation of solid catalyst system, thus serving as “internal electron donors”, or they may be employed during or prior to polymerization with the co-catalyst as “external electron donors”.
    Type: Grant
    Filed: November 1, 2013
    Date of Patent: April 24, 2018
    Assignee: Formosa Plastics Corporation, U.S.A.
    Inventors: Yiqun Fang, Demin Xu, Ming-Yung Lee
  • Patent number: 9815918
    Abstract: What is disclosed is a method for preparing a catalyst system and a catalyst system for polymerizing or copolymerizing an ?-olefin. Catalyst component (A) is obtained by a process of reacting a magnesium complex (A-1) containing acid salts of group IB-VIIIB elements formed by contacting a magnesium halide with an acid salt solution of group IB-VIIIB metals or spherical particles adducts, an internal electron donor (A-2) of diester or diether or composite compounds, and a titanium compound (A-3). The catalyst compound (A) is contacted with a silicon compound (B) and an organoaluminium compound (C) to complete the catalyst system providing a good balance of catalyst performance in terms of activity and stereo-specificity.
    Type: Grant
    Filed: March 19, 2012
    Date of Patent: November 14, 2017
    Assignee: Formosa Plastics Corporation, U.S.A.
    Inventor: Demin Xu
  • Patent number: 8575283
    Abstract: Heterocyclic organic compounds are used as electron donors in conjunction with solid Ziegler-Natta type catalyst in processes in which polyolefins such as polypropylene are produced. The electron donors may be used in the preparation of solid catalyst system, thus serving as “internal electron donors”, or they may be employed during or prior to polymerization with the co-catalyst as “external electron donors”.
    Type: Grant
    Filed: June 28, 2012
    Date of Patent: November 5, 2013
    Assignee: Formosa Plastics Corporation, U.S.A.
    Inventors: Yiqun Fang, Demin Xu, Ming-Yung Lee
  • Publication number: 20130109820
    Abstract: Cyclic organosilicon compounds having a structure represented by the general formula and a method for using thereof as a component of catalysts for producing propylene polymer having a very high melt-flowability are disclosed. The cyclic organosilicon compounds are employed as external electron donors in Ziegler-Natta catalyst systems to dramatically improve the hydrogen response, and therefore the catalyst systems can be used to prepare polymer having high melt-flowability and high isotacticity at high yield.
    Type: Application
    Filed: October 28, 2011
    Publication date: May 2, 2013
    Applicant: FORMOSA PLASTICS CORPORATION, U.S.A.
    Inventors: Lei Zhang, Yiqun Fang
  • Patent number: 7790819
    Abstract: Cyclic organosilicon compounds that may be employed as an electron donor for polymerization catalyst systems, polymerization catalyst systems employing the cyclic organosilicon compounds as an electron donor, methods of making the polymerization catalyst systems, and polymerization processes to produce polyolefin are disclosed. The organosilicon compounds, which are useful as electron donors in polymerization catalyst systems for the production of polyolefins, are represented by the formula: where Q1, Q2, Q3, and Q4 may be identical or different and are each hetero-atoms selected from the group consisting of N, O, S, Si, B, and P. R1, R2, R3, and R4 may be identical or different and are each hydrocarbon-based substituents to Q1, Q2, Q3, and Q4, respectively. The subscripts i, j, m, and n are independently 0 to 3 R5 and R6 may be identical or different and are each a bridging group with a backbone chain length between the two hetero-atoms Q1 and Q3, and Q2 and Q4, respectively, 1-8 atoms.
    Type: Grant
    Filed: April 13, 2009
    Date of Patent: September 7, 2010
    Assignee: Formosa Plastics Corporation, U.S.A.
    Inventors: Yiqun Fang, Honglan Lu
  • Patent number: 7651969
    Abstract: A process for synthesizing a catalyst component for manufacturing ethylene polymer and co-polymer. The present invention provides a process for synthesizing catalyst component (A), comprising forming a complex by contacting the solid intermediate (B) with an aluminum compound represented by formula X3-nAl(OY)n, and alkyl metal (C), wherein X is halide, Y is a hydrocarbon group or chelating carbonyl group, and wherein 1 is less than or equal to n which is less than or equal to 3, and then contacting the complex with titanium halide having formula TiX4 wherein X is halide. Solid intermediate (B) is formed by reacting magnesium metal with alkyl halide in the presence of alkoxy aluminum represented by formula Al(ORa)3, silicon halide represented by formula SiX4 and alkoxy silane represented by formula Si(ORb)4, wherein Ra and Rb are an aromatic or aliphatic alkyl group and wherein X is halide.
    Type: Grant
    Filed: December 5, 2006
    Date of Patent: January 26, 2010
    Assignee: Formosa Plastics Corporation, U.S.A.
    Inventors: Gapgoung Kong, Zhongyang Liu, Honglan Lu