Patents by Inventor John F. Szul

John F. Szul 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: 6936675
    Abstract: A polyethylene film having a balance of improved physical and mechanical properties and a method for making the same are provided. In one aspect, the film includes a 1% secant modulus of greater than 25,000 psi, a dart impact resistance of greater than 500 g/mil, and a MD tear strength of greater than 500 g/mil. In one aspect, the method comprises reacting ethylene derived units and a comonomer in the presence of a hafnium-based metallocene at a temperature of from 70° C. and 90° C., an ethylene partial pressure of from 120 psia and 260 psia, and a comonomer to ethylene ratio of from 0.01 to 0.02 to produce an ethylene based polymer. The method further comprises extruding the ethylene based polymer at conditions sufficient to produce a polyethylene film comprising a secant modulus of greater than 25,000 psi, a dart impact resistance of greater than 500 g/mil, and a MD tear strength of greater than 500 g/mil.
    Type: Grant
    Filed: December 15, 2003
    Date of Patent: August 30, 2005
    Assignee: Univation Technologies, LLC
    Inventors: John F. Szul, James McLeod Farley, Laughlin G. McCullough, Ryan Winston Impelman
  • Patent number: 6897273
    Abstract: This invention relates to a process to polymerize olefin(s) comprising combining a solution, slurry or solid comprising one or more bulky ligand metallocene catalyst compounds, an optional support, and or one or more activator(s) with a solution comprising one or more phenoxide catalyst compounds, and thereafter, introducing one or more olefin(s) and the combination into a polymerization reactor. This invention also relates to a polymer of ethylene wherein the polymer has a density of 0.910 to 0.930 g/cc, a melt index of 0.3 to 2.0 dg/min, and a 15 to 35 ?m thick film of the polymer has a 45° gloss of 60 or more, a haze of 7% or less, and a dart impact of 600 g or more.
    Type: Grant
    Filed: December 4, 2000
    Date of Patent: May 24, 2005
    Assignee: Univation Technologies, LLC
    Inventors: John F. Szul, Tae Hoon Kwalk, David James Schreck, Simon Mawson, Matthew G. McKee, Kersten Anne Terry, Mark G. Goode, Gregory T. Whiteker, Eric A. Lucas
  • Patent number: 6894128
    Abstract: Catalyst compositions and methods useful in polymerization processes utilizing at least two metal compounds are disclosed. At least one of the metal compounds is a Group 15 containing metal compound and the other metal compound is preferably a bulky ligand metallocene-type catalyst. The invention also discloses a new polyolefin, generally polyethylene, particularly a multimodal polymer and more specifically, a bimodal polymer, and its use in various end-use applications such as film, molding and pipe. The Group 15 containing metal compound is represented in one embodiment by the formulae: wherein M is a Group 4, 5, or 6 metal; each X is independently a leaving group; y is 0 or 1; n is the oxidation state of M; m is the formal change of the ligand comprising the YZL or YZL? groups; L is a Group 15 or 16 element; L? is a Group 15 or 16 element or Group 14 containing group; Y is a Group 15 element; Z is a Group 15 element; and the other groups are as defined herein.
    Type: Grant
    Filed: August 5, 2003
    Date of Patent: May 17, 2005
    Assignee: Univation Technologies, LLC
    Inventors: Donald R. Loveday, David H. McConville, John F. Szul, Kersten Anne Erickson, Simon Mawson, Tae Hoon Kwack, Frederick J. Karol, David James Schreck
  • Patent number: 6841631
    Abstract: Catalyst compositions and methods, useful in polymerization processes, utilizing at least two metal compounds are disclosed. At least one of the metal compounds is a Group 15 containing metal compound and the other metal compound is preferably a bulky ligand metallocene-type catalyst. The invention also discloses a new polyolefin, generally polyethylene, particularly a multimodal polymer and more specifically, a bimodal polymer, and its use in various end-use applications such as film, molding and pipe.
    Type: Grant
    Filed: August 1, 2003
    Date of Patent: January 11, 2005
    Assignee: Univation Technologies, LLC
    Inventors: Donald R. Loveday, David H. McConville, John F. Szul, Kersten Anne Erickson, Simon Mawson, Tae Hoon Kwack, Frederick J. Karol, David James Schreck
  • Patent number: 6828394
    Abstract: The present invention provides polymerization catalyst compounds, catalyst systems including these catalyst compounds, and to their use in the polymerization of ethylene and at least one comonomer. In particular, the invention provides a catalyst system comprising a poor comonomer incorporating catalyst compound and a good comonomer incorporating catalyst compound. Preferably, the low comonomer incorporating catalyst compound is a metallocene containing at least one substituted or unsubstituted fused ring cyclopentadienyl based ligand which is substantially directed to the front of the molecule, contains a long bridging group, or which contains a methyl substitution pattern which correlates to poor comonomer incorporation. The invention also provides methods of selecting the poor comonomer incorporating metallocene to pair with the good comonomer incorporating metallocene to produce polymers that are easy to process into a variety of articles, especially polyethylene based film, having enhanced properties.
    Type: Grant
    Filed: July 19, 2002
    Date of Patent: December 7, 2004
    Assignee: Univation Technologies, LLC
    Inventors: George Alan Vaughan, John F. Szul, Matthew Gary McKee, James McLeod Farley, Ching-Tai Lue, Sun-Chueh Kao
  • Publication number: 20040241483
    Abstract: Metallocene catalyzed polyethylenes are found to have improved physical properties, improved processability and improved balance of properties. Surprisingly, there is a direct relationship between MD shrinkage, and MD tear. Additionally, MD tear is greater than TD tear, and MD tear is also greater than intrinsic tear. MD tear to TD tear ratios are above 0.9, and dart drop impact is above 500 g/mil. The polyethylenes have a relatively broad composition distribution and relatively broad molecular weight distribution.
    Type: Application
    Filed: June 15, 2004
    Publication date: December 2, 2004
    Inventors: James McLeod Farley, John F. Szul, Matthew Gary McKee
  • Publication number: 20040225088
    Abstract: The present invention provides polymerization catalyst compounds, catalyst systems including these catalyst compounds, and to their use in the polymerization of ethylene and at least one comonomer. In particular, the invention provides a catalyst system comprising a poor comonomer incorporating catalyst compound and a good comonomer incorporating catalyst compound. Preferably, the low comonomer incorporating catalyst compound is a metallocene containing at least one substituted or unsubstituted fused ring cyclopentadienyl based ligand which is substantially directed to the front of the molecule, contains a long bridging group, or which contains a methyl substitution pattern which correlates to poor comonomer incorporation. The invention also provides methods of selecting the poor comonomer incorporating metallocene to pair with the good comonomer incorporating metallocene to produce polymers that are easy to process into a variety of articles, especially polyethylene based film, having enhanced properties.
    Type: Application
    Filed: April 2, 2004
    Publication date: November 11, 2004
    Inventors: George Alan Vaughan, John F. Szul, Matthew Gary McKee, James McLeod Farley, Ching-Tai Lue, Sun-Chueh Kao
  • Patent number: 6696537
    Abstract: A polymer produced by a polymerization process, in the gas or slurry phase, with a liquid carrier comprising an activator and a metal catalyst compound comprising a group 3 to 14 metal atom bound to at least one anionic leaving group and also bound to at least two group 15 atoms, at least one of which is also bound to a group 15 or 16 atom through another group which may be a C1 to C20 hydrocarbon group, a heteroatom containing group, silicon, germanium, tin, lead, phosphorus, or a halogen, wherein the group 15 or 16 atom may also be bound to nothing or a hydrogen, a group 14 atom containing group, a halogen, or a heteroatom containing group, and wherein each of the two group 15 atoms are also bound to a cyclic group and may optionally be bound to hydrogen, a halogen, a heteroatom or a hydrocarbyl group, or a heteroatom containing group.
    Type: Grant
    Filed: May 16, 2002
    Date of Patent: February 24, 2004
    Assignee: Univation Technologies, LLC
    Inventors: David H. McConville, John F. Szul, Donald R. Loveday
  • Publication number: 20040034179
    Abstract: Catalyst compositions and methods, useful in polymerization processes, utilizing at least two metal compounds are disclosed. At least one of the metal compounds is a Group 15 containing metal compound and the other metal compound is preferably a bulky ligand metallocene-type catalyst. The invention also discloses a new polyolefin, generally polyethylene, particularly a multimodal polymer and more specifically, a bimodal polymer, and its use in various end-use applications such as film, molding and pipe.
    Type: Application
    Filed: August 1, 2003
    Publication date: February 19, 2004
    Inventors: Donald R. Loveday, David H. McConville, John F. Szul, Kersten Anne Erickson, Simon Mawson, Tae Hoon Kwack, Frederick J. Karol, David James Schreck
  • Publication number: 20040030070
    Abstract: Catalyst compositions and methods, useful in polymerization processes, utilizing at least two metal compounds are disclosed. At least one of the metal compounds is a Group 15 containing metal compound and the other metal compound is preferably a bulky ligand metallocene-type catalyst. The invention also discloses a new polyolefin, generally polyethylene, particularly a multimodal polymer and more specifically, a bimodal polymer, and its use in various end-use applications such as film, molding and pipe.
    Type: Application
    Filed: August 5, 2003
    Publication date: February 12, 2004
    Inventors: Donald R. Loveday, David H. McConville, John F. Szul, Kersten Anne Erickson, Simon Mawson, Tae Hoon Kwack, Frederick J. Karol, David James Schreck
  • Publication number: 20040030066
    Abstract: Catalyst compositions and methods, useful in polymerization processes, utilizing at least two metal compounds are disclosed. At least one of the metal compounds is a Group 15 containing metal compound and the other metal compound is preferably a bulky ligand metallocene-type catalyst. The invention also discloses a new polyolefin, generally polyethylene, particularly a multimodal polymer and more specifically, a bimodal polymer, and its use in various end-use applications such as film, molding and pipe.
    Type: Application
    Filed: August 6, 2003
    Publication date: February 12, 2004
    Inventors: Donald R. Loveday, David H. McConville, John F. Szul, Kersten Anne Erickson, Simon Mawson, Tae Hoon Kwack, Frederick J. Karol, David James Schreck
  • Patent number: 6586544
    Abstract: This invention relates to methods to introduce multiple catalysts, activators or catalyst systems into a gas phase reactor.
    Type: Grant
    Filed: April 15, 2002
    Date of Patent: July 1, 2003
    Assignee: Univation Technologies, LLC
    Inventors: John F. Szul, Kersten Anne Erickson, Simon Mawson, David James Schreck, Mark G. Goode, Paul T. Daniell, Matthew G. McKee, Clark C. Williams
  • Publication number: 20030096128
    Abstract: Metallocene catalyzed polyethylenes are found to have improved physical properties, improved processability and improved balance of properties. Surprisingly, there is a direct relationship between MD shrinkage, and MD tear. Additionally, MD tear is greater than TD tear, and MD tear is also greater than intrinsic tear. MD tear to TD tear ratios are above 0.9, and dart drop impact is above 500 g/mil. The polyethylenes have a relatively broad composition distribution and relatively broad molecular weight distribution.
    Type: Application
    Filed: July 19, 2002
    Publication date: May 22, 2003
    Inventors: James McLeod Farley, John F. Szul, Matthew Gary McKee
  • Patent number: 6566462
    Abstract: This invention relates to a process to polymerize olefins comprising reacting olefins with a catalyst system comprising an activator, a metallocene and a second metal compound based on bidentate ligands containing heterocycle moieties.
    Type: Grant
    Filed: October 10, 2001
    Date of Patent: May 20, 2003
    Assignee: Univation Technologies, LLC
    Inventors: Rex E. Murray, Simon Mawson, John F. Szul, Kersten Anne Erickson, Tae Hoon Kwack, Frederick J. Karol, David James Schreck
  • Publication number: 20030088038
    Abstract: The present invention provides polymerization catalyst compounds, catalyst systems including these catalyst compounds, and to their use in the polymerization of ethylene and at least one comonomer. In particular, the invention provides a catalyst system comprising a poor comonomer incorporating catalyst compound and a good comonomer incorporating catalyst compound. Preferably, the low comonomer incorporating catalyst compound is a metallocene containing at least one substituted or unsubstituted fused ring cyclopentadienyl based ligand which is substantially directed to the front of the molecule, contains a long bridging group, or which contains a methyl substitution pattern which correlates to poor comonomer incorporation. The invention also provides methods of selecting the poor comonomer incorporating metallocene to pair with the good comonomer incorporating metallocene to produce polymers that are easy to process into a variety of articles, especially polyethylene based film, having enhanced properties.
    Type: Application
    Filed: July 19, 2002
    Publication date: May 8, 2003
    Inventors: George Alan Vaughan, John F. Szul, Matthew Gary McKee, James McLeod Farley, Ching-Tai Lue, Sun-Chueh Kao
  • Patent number: 6534604
    Abstract: Catalyst compositions and methods, useful in polymerization processes, utilizing at least two metal compounds are disclosed. At least one of the metal compounds is a Group 15 containing metal compound and the other metal compound is preferably a bulky ligand metallocene-type catalyst. The invention also discloses a new polyolefin, generally polyethylene, particularly a multimodal polymer and more specifically, a bimodal polymer, and its use in various end-use applications such as film, molding and pipe.
    Type: Grant
    Filed: May 24, 2001
    Date of Patent: March 18, 2003
    Assignee: Univation Technologies, LLC
    Inventors: Donald R. Loveday, David H. McConville, John F. Szul, Kersten Anne Erickson, Simon Mawson, Tae Hoon Kwack, Frederick J. Karol, David James Schreck
  • Publication number: 20020198351
    Abstract: A polymer produced by a polymerization process, in the gas or slurry phase, with a liquid carrier comprising an activator and a metal catalyst compound comprising a group 3 to 14 metal atom bound to at least one anionic leaving group and also bound to at least two group 15 atoms, at least one of which is also bound to a group 15 or 16 atom through another group which may be a C1 to C20 hydrocarbon group, a heteroatom containing group, silicon, germanium, tin, lead, phosphorus, or a halogen, wherein the group 15 or 16 atom may also be bound to nothing or a hydrogen, a group 14 atom containing group, a halogen, or a heteroatom containing group, and wherein each of the two group 15 atoms are also bound to a cyclic group and may optionally be bound to hydrogen, a halogen, a heteroatom or a hydrocarbyl group, or a heteroatom containing group.
    Type: Application
    Filed: May 16, 2002
    Publication date: December 26, 2002
    Inventors: David H. McConville, John F. Szul, Donald R. Loveday
  • Publication number: 20020111443
    Abstract: This invention relates to methods to introduce multiple catalysts, activators or catalyst systems into a gas phase reactor.
    Type: Application
    Filed: April 15, 2002
    Publication date: August 15, 2002
    Inventors: John F. Szul, Kersten Anne Erickson, Simon Mawson, David James Schreck, Mark G. Goode, Paul T. Daniell, Matthew G. McKee, Clark C. Williams
  • Publication number: 20020107341
    Abstract: This invention relates to a process to polymerize olefins comprising reacting olefins with a catalyst system comprising an activator, a metallocene and a second metal compound based on bidentate ligands containing heterocycle moieties.
    Type: Application
    Filed: October 10, 2001
    Publication date: August 8, 2002
    Inventors: Rex E. Murray, Simon Mawson, John F. Szul, Kersten Anne Erickson, Tae Hoon Kwack, Frederick J. Karol, David James Schreck
  • Publication number: 20020103310
    Abstract: This invention relates to a process to polymerize olefin(s) comprising combining a solution, slurry or solid comprising one or more bulky ligand metallocene catalyst compounds, an optional support, and or one or more activator(s) with a solution comprising one or more phenoxide catalyst compounds, and thereafter, introducing one or more olefin(s) and the combination into a polymerization reactor. This invention also relates to a polymer of ethylene wherein the polymer has a density of 0.910 to 0.930 g/cc, a melt index of 0.3 to 2.0 dg/min, and a 15 to 35 &mgr;m thick film of the polymer has a 45° gloss of 60 or more, a haze of 7% or less, and a dart impact of 600 g or more.
    Type: Application
    Filed: December 4, 2000
    Publication date: August 1, 2002
    Inventors: John F. Szul, Tae Hoon Kwalk, David James Schreck, Simon Mawson, Matthew G. McKee, Kersten Anne Terry, Mark G. Goode, Gregory T. Whiteker, Eric A. Lucas