Patents by Inventor Frederick J. Karol
Frederick J. Karol 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).
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Patent number: 4482687Abstract: Ethylene copolymers having a density of about 0.91 to 0.94 and a melt flow ratio of about .gtoreq.26 to .ltoreq.40 are readily produced in a low pressure gas phase process at a productivity of .gtoreq.500,000 pounds of polymer per pound of Ti with a catalyst formed from selected organo aluminum compounds and a composition prepared by copulverizing magnesium dihalide with a complex obtained by contacting a titanium compound of the structure Ti(OR).sub.a X.sub.b with an ether, ester, ketone or amine,wherein R is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, or COR' where R' is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical,X is Cl, Br, I or mixtures thereof, a is 0 or 1, b is 2 to 4 inclusive and a+b=3 or 4.Type: GrantFiled: June 24, 1983Date of Patent: November 13, 1984Assignee: Union Carbide CorporationInventors: Allen Noshay, Frederick J. Karol, Robert J. Jorgensen
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Patent number: 4460755Abstract: A method of converting a continuous olefin polymerization reaction catalyzed by a Ziegler-type catalyst into one catalyzed by a chromium-based catalyst, without the need of emptying and recharging the polymerization reactor, by adding a hydroxyl-containing compound to the reactor containing the Ziegler-type catalyst to interact with such catalyst before the chromium-based catalyst is introduced into the reactor.Type: GrantFiled: October 28, 1982Date of Patent: July 17, 1984Assignee: Union Carbide CorporationInventors: Gary H. Williams, Frederick J. Karol
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Patent number: 4427573Abstract: Catalyst compositions suitable for producing ethylene polymers in a low pressure gas phase process are produced by forming a partially activated precursor composition from a magnesium compound, titanium compound, inert carrier material and an organoaluminum activator compound in an electron donor solvent.Type: GrantFiled: September 16, 1981Date of Patent: January 24, 1984Assignee: Union Carbide CorporationInventors: David L. Miles, Frederick J. Karol, George L. Goeke
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Patent number: 4395359Abstract: A catalyst formed from selected organo aluminum compounds and a precursor composition of the formulaMg.sub.m Ti.sub.1 (OR).sub.n X.sub.p [ED].sub.qwhereinED is a selected electron donor compoundm is .gtoreq.0.5 to .ltoreq.56n is 0 or 1p is .gtoreq.6 to .ltoreq.116q is .gtoreq.2 to .ltoreq.85R is a C.sub.1 to C.sub.14, aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, andX is selected from the group consisting of Cl, Br, I,or mixtures thereof, which catalyst is in particulate from and diluted with an inert carrier material; a process for preparing such catalyst; a process for using said catalyst to readily prepare ethylene homopolymer having a density of about .gtoreq.0.958 to .ltoreq.0.972 and a melt flow ratio of .gtoreq.22 to .ltoreq.32 in a low pressure gas phase process at a productivity of .gtoreq.50,000 pounds of polymer per pound of Ti. Novel polymers and molded articles are prepared.Type: GrantFiled: March 31, 1981Date of Patent: July 26, 1983Assignee: Union Carbide CorporationInventors: Burkhard E. Wagner, Frederick J. Karol, George L. Goeke, Robert J. Jorgensen, Nils Friis
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Patent number: 4390677Abstract: An article molded from ethylene hydrocarbon copolymers, which articles have superior stress crack resistance and low temperature toughness.Type: GrantFiled: February 27, 1979Date of Patent: June 28, 1983Inventors: Frederick J. Karol, George L. Goeke, Burkhard E. Wagner, William A. Fraser, Robert J. Jorgensen, Nils Friis
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Patent number: 4383095Abstract: A catalytic process for preparing ethylene polymers having a density of .gtoreq.0.95 to .ltoreq.0.97 and a melt flow ratio of about .gtoreq.22 to .ltoreq.32 in a low pressure gas phase process at a productivity of .gtoreq.50,000 pounds of polymer per pound of Ti with a catalyst formed from selected organoaluminum compounds and a precursor composition of the formulaMg.sub.m Ti.sub.1 (OR).sub.n X.sub.p [ED].sub.qwherein ED is a selected electron donor compoundm is .gtoreq.0.5 to .ltoreq.56n is 0, 1 or 2p is .gtoreq.2 to .ltoreq.116q=1.5 m+2R is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, andX is selected from the group consisting of Cl, Br, I or mixtures thereof,which catalyst is in particulate form and impregnated in a porous inert carrier material.Type: GrantFiled: November 20, 1981Date of Patent: May 10, 1983Assignee: Union Carbide CorporationInventors: George L. Goeke, Burkhard E. Wagner, Frederick J. Karol
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Patent number: 4379758Abstract: Catalyst compositions suitable for producing high density ethylene polymers in a low pressure gas phase process with low accompanying ethylene hydrogenation are produced by forming a precursor composition from a magnesium compound, titanium compound and electron donor compound; diluting said precursor composition with an inert carrier material; treating said diluted precursor composition with a boron halide compound; and activating the precursor composition with an organo aluminum compound.Type: GrantFiled: December 24, 1980Date of Patent: April 12, 1983Assignee: Union Carbide CorporationInventors: Burkhard E. Wagner, George L. Goeke, Frederick J. Karol, Kathleen F. George
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Patent number: 4379759Abstract: A catalyst formed from selected organc aluminum compounds and a precursor composition of the formulaMg.sub.m Ti.sub.1 (OR).sub.n X.sub.p [ED].sub.qwherein ED is a selected electron donor compoundm is .gtoreq.0.5 to .ltoreq.56n is 0, 1 or 2p is .gtoreq.2 to .ltoreq.116q is .gtoreq.2 to .ltoreq.85R is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a Chd 1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, andX is selected from the group consisting of Cl, Br, I or mixtures thereof,which catalyst is in particulate form and impregnated in a porous inert carrier material.A process for preparing such catalyst.A process for using said catalyst to readily prepared ethylene copolymers having a density of about .gtoreq.0.91 to .ltoreq.0.94 and a melt flow ratio of .gtoreq.22 to .ltoreq.32 in a low pressure gas phase process at a productivity of .gtoreq.50,000 pounds of polymer per pound of Ti.Novel polymers and molded articles are prepared.Type: GrantFiled: May 15, 1981Date of Patent: April 12, 1983Assignee: Union Carbide CorporationInventors: George L. Goeke, Burkhard E. Wagner, Frederick J. Karol
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Patent number: 4376062Abstract: A catalyst composition formed from selected organoaluminum compounds and a precursor composition of the formulaMg.sub.m Ti.sub.l (OR).sub.n X.sub.p [ED].sub.q [Filler].sub.rwherein ED is a selected electron donor compoundR is a C.sub.1 to C.sub.14, aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, X is Cl, Br, I, or mixtures thereof, Filler is an inert organic or inorganic compound, and, based on the total weight of such compositionm is .gtoreq.0.5 to .ltoreq.56n is 0 or 1p is .gtoreq.6 to .ltoreq.116q is .gtoreq.2 to .ltoreq.85r has a value such that the percent filler is from about 10 to about 95 weight percent based on the total weight of the precursor composition.A process for preparing such precursor composition by spray drying it from a slurry or solution in said electron donor compound, using atomization.A process for using said catalyst to readily prepare ethylene polymers having a density of about .gtoreq.0.91 to .ltoreq.Type: GrantFiled: March 31, 1981Date of Patent: March 8, 1983Assignee: Union Carbide CorporationInventors: Anthony D. Hamer, Frederick J. Karol
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Patent number: 4363904Abstract: Heterogeneous ethylene based hydrocarbon copolymers having high tear strength properties in film form, formed from ethylene, C.sub.3-4 monomer and C.sub.5-8 monomer with a molar ratio in the polymer of (C.sub.3-4 /C.sub.2) of about 0.006 to 0.09, a (C.sub.5-8 /C.sub.2) ratio of about 0.003 to 0.07 and having a Chain Branch Factor of about 0.2 to 0.8 and a narrow molecular weight distribution; a gas phase process for making such polymers, and film made from such polymers.Type: GrantFiled: March 23, 1981Date of Patent: December 14, 1982Assignee: Union Carbide CorporationInventors: William A. Fraser, Norma J. Maraschin, Frederick J. Karol, Alexander J. Makai
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Patent number: 4359561Abstract: Heterogeneous ethylene based hydrocarbon copolymers having high tear strength properties in film form, formed from ethylene, C.sub.3-4 monomer and C.sub.5-8 monomer with a molar ratio in the polymer of C.sub.3-4 /C.sub.2 of about 0.006 to 0.09, a C.sub.5-8 /C.sub.2 ratio of about 0.003 to 0.07 and having a Chain Branch Factor of about 0.2 to 0.8 and a narrow molecular weight distribution; a gas phase process for making such polymers, and film made from such polymers.Type: GrantFiled: March 23, 1981Date of Patent: November 16, 1982Assignee: Union Carbide CorporationInventors: William A. Fraser, Norma J. Maraschin, Frederick J. Karol, Alexander J. Makai
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Patent number: 4354009Abstract: The copolymerization of ethylene with other alpha olefins in a low pressure gas phase reaction is improved with the use of a catalyst composition prepared by forming a precursor composition from a magnesium compound, titanium compound and electron donor compound; diluting said precursor composition with an inert carrier material; treating said diluted precursor composition with a hydrocarbyl aluminum dihalide compound; and activating the precursor composition treated in this manner with an organo aluminum compound.Type: GrantFiled: July 30, 1981Date of Patent: October 12, 1982Assignee: Union Carbide CorporationInventors: George L. Goeke, Burkhard E. Wagner, Frederick J. Karol
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Patent number: 4349648Abstract: Ethylene copolymers having improved optical properties in film form are prepared by continuously copolymerizing ethylene with one or more higher alpha olefin monomers in a low pressure gas phase reaction with a catalyst composition prepared by forming a precursor composition from a magnesium compound, titanium compound, and electron donor compound; diluting said precursor composition with an inert carrier material; optionally partially activating the diluted precursor composition with an organo aluminum compound prior to introducing said diluted precursor composition into the polymerization reactor; and completely activating the diluted (and optionally partially activated) precursor composition in the polymerization reactor with a mixture of a dihydrocarbyl aluminum halide compound and a trihydrocarbyl aluminum compound.Type: GrantFiled: July 31, 1981Date of Patent: September 14, 1982Assignee: Union Carbide CorporationInventors: Robert J. Jorgensen, George L. Goeke, Frederick J. Karol
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Patent number: 4303771Abstract: A catalytic process for preparing ethylene polymers having a density of .gtoreq.0.94 to .ltoreq.0.97 and a melt flow ratio of about .gtoreq.22 to .ltoreq.32 in a low pressure gas phase process at a productivity of .gtoreq.50,000 pounds of polymer per pound of Ti with a catalyst formed from selected organoaluminum compounds and a precursor composition of the formulaMg.sub.m Ti.sub.1 (OR).sub.n X.sub.p (ED).sub.qwherein ED is a selected electron donor compoundm is .gtoreq.0.5 to .ltoreq.56n is 0, 1 or 2p is .gtoreq.2 to .ltoreq.116q is >1.5 m+2R is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, andX is selected from the group consisting ofCl, Br, I or mixtures thereof,which catalyst is in particulate form and impregnated in a porous inert carrier material.Type: GrantFiled: February 16, 1979Date of Patent: December 1, 1981Assignee: Union Carbide CorporationInventors: Burkhard E. Wagner, George L. Goeke, Frederick J. Karol
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Patent number: 4302565Abstract: A catalyst formed from selected organo aluminum compounds and a precursor composition of the formulaMg.sub.m Ti.sub.l (OR).sub.n X.sub.p [ED].sub.qwherein ED is a selected electron donor compoundm is .gtoreq.0.5 to .ltoreq.56n is 0, 1 or 2p is .ltoreq.2 to .gtoreq.116q is .gtoreq.2 to .ltoreq.85R is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, andX is selected from the group consisting of Cl, Br, I or mixtures thereof,which catalyst is in particulate form and impregnated in a porous inert carrier material.A process for preparing such catalyst.A process for using said catalyst to readily prepare ethylene copolymers having a density of about .gtoreq.0.91 to .ltoreq.0.94 and a melt flow ratio of .gtoreq.22 to .ltoreq.32 in a low pressure gas phase process at a productivity of .gtoreq.50,000 pounds of polymer per pound of Ti.Novel polymers and molded articles are prepared.Type: GrantFiled: February 16, 1979Date of Patent: November 24, 1981Assignee: Union Carbide CorporationInventors: George L. Goeke, Burkhard E. Wagner, Frederick J. Karol
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Patent number: 4302566Abstract: Ethylene copolymers having a density of .gtoreq.0.91 to .ltoreq.0.96 and a melt flow ratio of .gtoreq.22 to .ltoreq.32 are readily produced in a low pressure gas phase process at a productivity of .gtoreq.50,000 pounds of polymer per pound of Ti with a particulate catalyst diluted with an inert carrier material and formed from selected organo aluminum compounds and a precursor composition of the formula:Mg.sub.m Ti.sub.1 (OR).sub.n X.sub.p [ED].sub.qwherein ED is a selected electron donor compound.m is .gtoreq.0.5 to .ltoreq.56n is 0 or 1p is .gtoreq.6 to .ltoreq.116q is .gtoreq.2 to .ltoreq.85R is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, andX is selected from the group consisting of Cl, Br, I, or mixtures thereof.Type: GrantFiled: February 27, 1979Date of Patent: November 24, 1981Assignee: Union Carbide CorporationInventors: Frederick J. Karol, George L. Goeke, Burkhard E. Wagner, William A. Fraser, Robert J. Jorgensen, Nils Friis
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Patent number: 4293673Abstract: A catalyst composition formed from selected organoaluminum compounds and a precursor composition of the formulaMg.sub.m Ti.sub.1 (OR).sub.n X.sub.p [ED].sub.q [Filler].sub.rwhereinED is a selected electron donor compoundR is a C.sub.1 to C.sub.14, aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a C.sub.1 to C.sub.14 aliphatic or aromatic hydrocarbon radical, X is Cl, Br, I, or mixtures thereof, Filler is an inert organic or inorganic compound, and, based on the total weight of such compositionm is .gtoreq.0.5 to .ltoreq.56n is 0 or 1p is .gtoreq.6 to .ltoreq.116q is .gtoreq.2 to .ltoreq.5r has a value such that the percent filler is from about 10 to about 95 weight percent based on the total weight of the precursor composition. A process for preparing such precursor composition by spray drying it from a slurry or solution in said electron donor compound, using atomization. A process for using said catalyst to readily prepare ethylene polymers having a density of about .gtoreq.0.91 to .ltoreq.Type: GrantFiled: November 28, 1979Date of Patent: October 6, 1981Assignee: Union Carbide CorporationInventors: Anthony D. Hamer, Frederick J. Karol
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Patent number: 4267309Abstract: In a process for the preparation of an olefin oxide polymerization catalyst comprising:(i) admixing calcium, ammonia, an alkylene oxide modifier, and an organic nitrile modifier, the alkylene oxide consisting of carbon, hydrogen, and oxirane oxygen atoms and the organic nitrile consisting of carbon, nitrogen, and hydrogen atoms, at least one hydrogen atom being acidic, to form a slurry of modified calcium hexammine in ammonia; and(ii) evaporating ammonia to provide a solid residue,the improvement comprising:aging the solid residue at a temperature in the range of about 150.degree. C. to about 225.degree. C.Type: GrantFiled: January 31, 1980Date of Patent: May 12, 1981Assignee: Union Carbide CorporationInventors: George L. Goeke, Frederick J. Karol
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Patent number: 4193892Abstract: In a process for the preparation of an olefin oxide polymerization catalyst comprising:(i) admixing calcium, ammonia, an alkylene oxide modifier, and an organic nitrile modifier, the alkylene oxide consisting of carbon, hydrogen, and oxirane oxygen atoms and the organic nitrile consisting of carbon, nitrogen, and hydrogen atoms, at least one hydrogen atom being acidic, to form a slurry of modified calcium hexammine in ammonia; and(ii) evaporating ammonia to provide a solid residue,the improvement comprising:aging the solid residue at a temperature in the range of about 150.degree. C. to about 225.degree. C.Type: GrantFiled: July 28, 1978Date of Patent: March 18, 1980Assignee: Union Carbide CorporationInventors: George L. Goeke, Frederick J. Karol
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Patent number: 4170589Abstract: An improved method for preparing ethylene polymers with certain supported chromium [II] catalysts wherein the improvement comprises employing said catalyst in the presence of phenolic antioxidant.Type: GrantFiled: February 22, 1978Date of Patent: October 9, 1979Assignee: Union Carbide CorporationInventors: George L. Goeke, Anthony D. Hamer, Frederick J. Karol