Patents by Inventor Frederick John Karol

Frederick John 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).

  • Patent number: 6562750
    Abstract: A catalyst composition for the polymerization of olefins is provided, comprising a bis(hydroxy aromatic nitrogen ligand) transition metal catalyst precursor and an activating cocatalyst.
    Type: Grant
    Filed: January 9, 2002
    Date of Patent: May 13, 2003
    Assignee: Univation Technologies
    Inventors: Walter Thomas Reichle, Frederick John Karol
  • Publication number: 20020077477
    Abstract: A catalyst composition for the polymerization of olefins is provided, comprising a bis(hydroxy aromatic nitrogen ligand) transition metal catalyst precursor and an activating cocatalyst.
    Type: Application
    Filed: January 9, 2002
    Publication date: June 20, 2002
    Inventors: Walter Thomas Reichle, Frederick John Karol
  • Patent number: 6380390
    Abstract: A catalyst composition for the polymerization of olefins is provided, comprising a bis(hydroxy aromatic nitrogen ligand) transition metal catalyst precursor and an activating cocatalyst.
    Type: Grant
    Filed: January 13, 2000
    Date of Patent: April 30, 2002
    Assignee: Univation Technologies, LLC
    Inventors: Walter Thomas Reichle, Frederick John Karol
  • Patent number: 6281320
    Abstract: This invention comprises a metallocene catalyst system for the production of high molecular weight polyolefins, particularly polyethylene and higher poly-alpha olefins, and copolymers of ethylene and/or alpha olefins with other unsaturated monomers, including diolefins, acetylenically unsaturated monomers and cyclic olefins. The catalyst system is highly active, at low ratios of Al to transition metal, and hence catalyzes the production of a polyolefin product containing low levels of catalyst metal residues. The catalyst system comprises (i) a metallocene precursor (Component A), aluminoxane (Component B), and phenolic modifier (Component C) or (ii) the reaction product of a metallocene precursor with a phenolic compound (Component A′) and aluminoxane (Component B). There is also provide a polymerization process using the catalyst and the product so produced.
    Type: Grant
    Filed: February 4, 1999
    Date of Patent: August 28, 2001
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Sun-Chueh Kao, Frederick John Karol
  • Patent number: 6232256
    Abstract: A catalyst composition is provided, which is prepared by contacting a cycloalkadienyl compound, a transition metal amide of the formula M(NMe2)mXn, an aluminoxane, and optionally a solid support at a temperature of 0 to 100° C.
    Type: Grant
    Filed: November 5, 1999
    Date of Patent: May 15, 2001
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Xinmin Yang, Walter Thomas Reichle, Frederick John Karol
  • Patent number: 6177527
    Abstract: A process for the preparation of (i) polyethylene or (ii) polypropylene, which is essentially isotactic or a mixture of atactic and isotactic polypropylenes comprising contacting ethylene or propylene per se, or in admixture with one or more alpha-olefins, under polymerization conditions, with a catalyst system comprising: (a) a precatalyst comprising a mixture of racemic and meso stereoisomers of a metallocene catalyst containing two cycloalkadienyl ligands joined by a bridging linkage, said ligands complexed to a metal atom; and (b) (1) to obtain polyethylene catalyzed by the rac epimer only, a cocatalyst selected from the group consisting of tris(perfluorophenyl)borane and isobutyl alumoxane;  (2) to obtain polyethylene catalyzed by both the rac and the meso epimers, a cocatalyst selected from the group consisting of dimethylanilinium tetrakis(perfluorophenyl)borate and triphenylmethyl tetrakis(perfluorophenyl)borate;  (3) to obtain polypropylene, which is essentially isotactic, a cocatalyst
    Type: Grant
    Filed: September 8, 1998
    Date of Patent: January 23, 2001
    Assignee: Union Carbide Chemical & Plastics Technology Corporation
    Inventors: Purna Chand Sishta, Xinmin Yang, Frederick John Karol
  • Patent number: 6159617
    Abstract: Ethylene polymers having a) a Polydispersity Index of about 2 to about 4; b) a melt index, MI, and Relaxation Spectrum Index, RSI, such that (RSI)(MI.sup.0.6) is about 2.5 to about 6.5; c) a Crystallizable Chain Length Distribution Index, L.sub.w /L.sub.n, of about 1.0 to about 9; and d) a density, .rho., and a percent haze when fabricated into films such that the percent haze is less than 370.rho.-330, are provided. These ethylene polymers advantageously combine superior clarity and toughness with low extractables and enhanced processing ease.
    Type: Grant
    Filed: April 2, 1998
    Date of Patent: December 12, 2000
    Assignee: Univation Technologies, LLC
    Inventors: George Norris Foster, Tong Chen, Robert Harold Vogel, Scott Hanley Wasserman, Day-Chyuan Lee, Walter Thomas Reichle, Frederick John Karol, Gregory Todd Whiteker
  • Patent number: 6136747
    Abstract: A mixed catalyst composition comprising a) a solid Ziegler-Natta catalyst; b) a liquid single site catalyst; and c) at least one activating cocatalyst is provided. Polymers having a broad or bimodal molecular weight distribution may be made with this catalyst composition.
    Type: Grant
    Filed: June 19, 1998
    Date of Patent: October 24, 2000
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Sun-Chueh Kao, Frederick John Karol, Paul Theodore Daniell, Gregory Mark Goode
  • Patent number: 6093824
    Abstract: A catalyst composition for the polymerization of olefins is provided, comprising a bis(hydroxy aromatic nitrogen ligand) transition metal catalyst precursor and an activating cocatalyst.
    Type: Grant
    Filed: February 25, 1998
    Date of Patent: July 25, 2000
    Assignee: Univation Technologies, LLC
    Inventors: Walter Thomas Reichle, Frederick John Karol
  • Patent number: 6069213
    Abstract: It has been found that the use of at least one unsupported metallocene polymerization catalyst with at least one supported metallocene polymerization catalyst in the polymerization of olefins allows for better control of the polymerization, especially gas phase polymerization. Such a system takes advantage of the high activity of the unsupported catalyst and the stability of a supported catalyst. Additionally, the relative timing of the addition of the supported and unsupported catalysts to a reaction system can be used to control a continuous polymerization reaction by stabilizing the reactor bed with the supported catalyst prior to addition of the unsupported catalyst.
    Type: Grant
    Filed: December 16, 1997
    Date of Patent: May 30, 2000
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Thomas Lloyd Nemzek, Frederick John Karol, Sun-Chueh Kao, Robert Converse Brady, III
  • Patent number: 6069109
    Abstract: A process for the production of a catalyst precursor comprising reacting (a) a metallocene dihalide; (b) a compound of the formula: ##STR1## wherein each Q is the same or different and is independently selected from the group consisting of O, NR, CR.sub.2, and S; E is either C or S; Z is selected from the group consisting of --OR, --NR.sub.2, --CR.sub.3, --SR, --SiR.sub.3, --PR.sub.2, --H, and a substituted or unsubstituted aryl group; and each R is independently a group containing carbon, silicon, nitrogen, oxygen, and/or phosphorus; and (c) a trialkylamine.
    Type: Grant
    Filed: July 1, 1998
    Date of Patent: May 30, 2000
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Sun-Chueh Kao, Frederick John Karol
  • Patent number: 6066703
    Abstract: A process for the polymerization of an olefin which employs as the catalyst composition the reaction product of a) a monocycloalkadienyl catalyst precursor; b) an activity enhancing cycloalkadiene; and c) an activating cocatalyst is disclosed.
    Type: Grant
    Filed: November 25, 1997
    Date of Patent: May 23, 2000
    Assignee: Univation Technologies LLC.
    Inventors: Walter Thomas Reichle, Xinmin Yang, Frederick John Karol
  • Patent number: 6028151
    Abstract: A process for producing an olefin polymer, which comprises contacting at least two olefin monomers under polymerization conditions with a catalyst composition comprising A) an aluminoxane-impregnated support prepared by contacting an aluminoxane with an inert carrier material and heating to a temperature of at least about 80.degree. C.; B) a metallocene of the formula:(L).sub.y (L')MY.sub.(x-y-1)wherein M is a metal from groups IIIB to VIII of the Periodic Table; each L and L' is independently a cycloalkadienyl group bonded to M; each Y is independently hydrogen, an aryl, alkyl, alkenyl, alkylaryl, or arylalkyl radical having 1-20 carbon atoms, a hydrocarboxy radical having from 1-20 carbon atoms, a halogen, RCO.sub.2 --, or R.sub.2 N--, wherein R is a hydrocarbyl group containing 1 to about 20 carbon atoms; y is 0, 1, or 2; x is 1, 2, 3, or 4; and x-y.gtoreq.1; C) a bulky aluminum alkyl of the formula:AlR.sup.1.sub.x R.sup.2.sub.(3-x)wherein R.sup.
    Type: Grant
    Filed: February 25, 1998
    Date of Patent: February 22, 2000
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Eric Paul Wasserman, Sun Chueh Kao, Frederick John Karol
  • Patent number: 5852146
    Abstract: A catalyst composition for the polymerization of olefins is provided, comprising a bis(hydroxy aromatic nitrogen ligand) transition metal catalyst precursor and an activating cocatalyst.
    Type: Grant
    Filed: June 27, 1996
    Date of Patent: December 22, 1998
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Walter Thomas Reichle, Frederick John Karol
  • Patent number: 5852143
    Abstract: Polyethylene having a broad molecular weight distribution, a narrow comonomer distribution and excellent processability is easily and cost effectively made using stereoisomeric mixtures of bridged metallocene catalysts containing cycloalkadienyl ligands with facial chirality.
    Type: Grant
    Filed: April 16, 1997
    Date of Patent: December 22, 1998
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Purna Chand Sishta, Eric Paul Wasserman, Frederick John Karol
  • Patent number: 5756416
    Abstract: A catalyst composition comprising A) an aluminoxane-impregnated support prepared by contacting an aluminoxane with an inert carrier material and heating to a temperature of at least about 80.degree. C.; B) a metallocene of the formula:(L).sub.y (L')MY.sub.(x-y-1)wherein M is a metal from groups IIIB to VIII of the Periodic Table; each L and L' is independently a cycloalkadienyl group bonded to M; each Y is independently hydrogen, an aryl, alkyl, alkenyl, alkylaryl, or arylalkyl radical having 1-20 carbon atoms, a hydrocarboxy radical having from 1-20 carbon atoms, a halogen, RCO.sub.2 --, or R.sub.2 N--, wherein R is a hydrocarbyl group containing 1 to about 20 carbon atoms; n and m are each 0, 1, 2, 3, or 4; y is 0, 1, or 2; x is 1, 2, 3, or 4; and x-y.gtoreq.1; C) a bulky aluminum alkyl of the formula:AlR.sup.1.sub.x R.sup.2.sub.(3-x)wherein R.sup.1 is a hydrocarbyl group having 1 to 12 carbon atoms; x is an integer from 0 to 2; R.sup.2 is a hydrocarbyl group of the formula --(CH.sub.2).sub.y -- R.sup.
    Type: Grant
    Filed: November 28, 1995
    Date of Patent: May 26, 1998
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Eric Paul Wasserman, Sun Chueh Kao, Frederick John Karol
  • Patent number: 5747406
    Abstract: A catalyst composition comprising the reaction product of a) a monocycloalkadienyl catalyst precursor; b) an activity enhancing cycloalkadiene; and c) an activating cocatalyst is disclosed, which has high activity in the polymerization of olefins.
    Type: Grant
    Filed: January 10, 1997
    Date of Patent: May 5, 1998
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Walter Thomas Reichle, Xinmin Yang, Frederick John Karol
  • Patent number: 5674795
    Abstract: Metallocene-containing catalyst compositions that include inert filler, a method for their preparation, and a method for their use in production of polyolefins are disclosed and claimed. The catalyst compositions contain solid particles of a mixture comprising a) a metallocene catalyst; b) a cocatalyst capable of activating said metallocene catalyst; and c) particulate filler material having an average particle size of less than about 10 micrometers that is unreactive with the metallocene catalyst and the cocatalyst. They are prepared by spray drying a slurry of the constituents.
    Type: Grant
    Filed: June 7, 1995
    Date of Patent: October 7, 1997
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Eric Paul Wasserman, Mark Wilton Smale, Timothy Roger Lynn, Robert Converse Brady, III, Frederick John Karol
  • Patent number: 5672669
    Abstract: Metallocene-containing catalyst compositions that include inert filler, a method for their preparation, and a method for their use in production of polyolefins are disclosed and claimed. The catalyst compositions contain solid particles of a mixture comprising a) a metallocene catalyst; b) a cocatalyst capable of activating said metallocene catalyst; and c) particulate filler material having an average particle size of less than about 10 micrometers that is unreactive with the metallocene catalyst and the cocatalyst. They are prepared by spray drying a slurry of the constituents.
    Type: Grant
    Filed: June 7, 1995
    Date of Patent: September 30, 1997
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Eric Paul Wasserman, Mark Wilton Smale, Timothy Roger Lynn, Robert Converse Brady III, Frederick John Karol
  • Patent number: 5648310
    Abstract: Metallocene-containing catalyst compositions that include inert filler, a method for their preparation, and a method for their use in production of polyolefins are disclosed and claimed. The catalyst compositions contain solid particles of a mixture comprising a) a metallocene catalyst; b) a cocatalyst capable of activating said metallocene catalyst; and c) particulate filler material having an average particle size of less than about 10 micrometers that is unreactive with the metallocene catalyst and the cocatalyst. They are prepared by spray drying a slurry of the constituents.
    Type: Grant
    Filed: June 26, 1995
    Date of Patent: July 15, 1997
    Assignee: Union Carbide Chemicals & Plastics Technology Corporation
    Inventors: Eric Paul Wasserman, Mark Wilton Smale, Timothy Roger Lynn, Robert Converse Brady, III, Frederick John Karol