Patents by Inventor Michael A. Leaf

Michael A. Leaf 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: 20260337388
    Abstract: Methods and compositions for processing polymers with fluorine-free polymer processing aids (PPAs) are described. The methods can include extruding a polymer composition, optionally with a masterbatch, wherein the polymer composition and/or the masterbatch comprises a fluorine-free PPA to make a polymeric film. The PPA comprises a mixture of one or more polyamides and one or more polyphosphites.
    Type: Application
    Filed: May 19, 2026
    Publication date: October 29, 2026
    Applicant: ExxonMobil Technology and Engineering Company
    Inventors: Michael A. Leaf, Danny Van Hoyweghen, Haiqing Peng, Petra M. Eiselt, Luke A. Galuska
  • Publication number: 20260317456
    Abstract: The present disclosure relates to catalysts, catalyst systems, polyethylene polymers, polymerization processes for making such polyethylene polymers, and films made therefrom. In some embodiments, a catalyst compound is represented by Formula (I) wherein M is Zr or Hf; R5 and R6 are each hydrogen; each of R1, R2, R3, and R4 is independently hydrogen or substituted or unsubstituted C1 to C10 alkyl; one of (1) R7 and R1, (2) R8 and R9, or (3) R9 and R10 are joined to form a substituted or unsubstituted aromatic ring or saturated ring fused to the indenyl ring shown in Formula (I), and the remainder of R7, R8, R9, and R10 are each hydrogen. In other embodiments a process for producing a polyethylene composition is provided, comprising introducing, under first polymerization conditions, ethylene and a C3-C40 alpha-olefin to a catalyst system in a reactor, and forming a polyethylene composition.
    Type: Application
    Filed: May 14, 2024
    Publication date: October 15, 2026
    Applicant: EXXONMOBIL TECHNOLOGY AND ENGINEERING COMPANY
    Inventors: Matthew W. Holtcamp, Dongming Li, Laughlin G. McCullough, Kevin A. Stevens, Michael A. Leaf, Ali H. Slim
  • Patent number: 12655240
    Abstract: Provided herein are metallocene-catalyzed polyethylene compositions that exhibit a high degree of broad orthogonal composition distribution (“BOCD”), meaning that they have a relatively high degree of short-chain branching in higher-molecular-weight chains, as compared to the short-chain branching in lower-molecular weight chains. The compositions may have 80 to 99.9 wt % units derived from ethylene and 0.1 to 20 wt % units derived from a C3 to C40 ?-olefin comonomer; density from 0.925 to 0.950 g/cm3, melt index (I2.16) within the range from 0.1 to 5 g/10 min, and molecular weight distribution (Mw/Mn) within the range from 4.0 to 8.0.
    Type: Grant
    Filed: November 22, 2021
    Date of Patent: June 16, 2026
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Wen Li, Haiqing Peng, Michael A. Leaf, Kevin A. Stevens
  • Publication number: 20260117053
    Abstract: Methods and compositions for processing polymers with fluorine-free polymer processing aids (PPAs) are described. The methods can include extruding a polymer composition, optionally with a masterbatch, wherein the polymer composition and/or the masterbatch comprises a fluorine-free PPA to make a polymeric film. The PPA comprises a mixture of one or more polyamides and one or more polyphosphites.
    Type: Application
    Filed: January 7, 2025
    Publication date: April 30, 2026
    Inventors: Michael A. LEAF, Danny Van Hoyweghen, Haiqing Peng, Petra M. Eiselt, Luke A. Galuska
  • Publication number: 20250329423
    Abstract: A method for producing a polymer includes generating polymer properties of the polymer using a model that includes an algorithm with an input of a cross-fractionation characterization (CFC) of the polymer. The CFC is generated based on a user input regarding one or more portions of the CFC. The method also includes producing the polymer having the polymer properties.
    Type: Application
    Filed: February 24, 2025
    Publication date: October 23, 2025
    Inventors: Michael A. LEAF, Hsu CHIANG, Jay L. REIMERS, Liezhong GONG, Donald A. WINESETT, Kevin A. STEVENS, Wen LI, Scott R. HORTON, Michael A. RISCH, Fred D. EHRMAN, Timothy D SHAFFER
  • Publication number: 20250145820
    Abstract: Methods and compositions for processing polymers with fluorine-free polymer processing aids (PPAs) are described. The methods can include extruding a polymer composition, the polymer composition optionally containing polyethylene glycol (PEG) polymer processing aid, to make a polymeric film; developing one or more melt fractures in the polymeric film; and in response to developing the one or more melt fractures, feeding a masterbatch of polymer processing agent. The masterbatch can include, and preferably can consist essentially of, 1 to 50 wt % PEG having weight average molecular weight (Mw) less than 10,000 g/mol; a carrier resin; and, optionally, one or more non-PPA additives.
    Type: Application
    Filed: December 14, 2022
    Publication date: May 8, 2025
    Inventors: Nino RUOCCO, Michael A. LEAF, Danny VAN HOYWEGHEN, Donald A. WINESETT
  • Publication number: 20250101224
    Abstract: Methods and compositions for processing polymers with fluorine-free polymer processing aids (PPAs) are described. The methods can include continuously extruding a polymer composition through an extruder to form a polymer product, and during at least a portion of the extruding, continually feeding a polyethylene glycol (PEG) composite to the extruder so that the PEG composite and polymer composition are coextruded through the extruder at conditions sufficient to melt blend the PEG composite and the polymer composition. The PEG composite can comprise or consist essentially of PEG (preferably PEG having weight average molecular weight less than 10,000 g/mol) and one or more non-PPA additives having melting point at 1 atm greater than that of the PEG.
    Type: Application
    Filed: December 14, 2022
    Publication date: March 27, 2025
    Inventors: Nino RUOCCO, Michael A. LEAF, Danny VAN HOYWEGHEN, Stephen E. DEHLINGER
  • Publication number: 20250084248
    Abstract: Methods and compositions for processing polymers with fluorine-free polymer processing aids (PPAs) are described. The methods can include continuously extruding a polymer composition through an extruder to form a polymer product, and during at least a portion of the extruding, continually feeding a polyethylene glycol (PEG) composite to the extruder so that the PEG composite and polymer composition are coextruded through the extruder at conditions sufficient to melt blend the PEG composite and the polymer composition. The PEG composite can comprise or consist essentially of PEG (preferably PEG having weight average molecular weight less than 10,000 g/mol) and one or polymers having melting point at 1 atm greater than that of the PEG.
    Type: Application
    Filed: February 8, 2023
    Publication date: March 13, 2025
    Inventors: Nino RUOCCO, Michael A. LEAF, Danny VAN HOYWEGHEN, Stephen E. DEHLINGER
  • Publication number: 20240400804
    Abstract: The present disclosure relates to polyethylene blends, films thereof, and methods thereof. In at least one embodiment, a polymer blend includes a first polyethylene having a density of about 0.94 g/cm3 to about 0.97 g/cm3 and a melt index of about 0.1 g/10 min to about 10 g/10 min. The blend includes a second polyethylene comprising at least 80 wt % ethylene derived-units. The second polyethylene has a density of about 0.918 g/cm3 to about 0.945 g/cm3, a number average molecular weight (Mn) of about 10,000 g/mol to about 20,000 g/mol, a weight-average molecular weight (Mw) of about 75,000 g/mol to about 300,000 g/mol, a melt index (2.16 kg) of about 0.1 g/10 min to about 5 g/10 min, a high load melt index (21.6 kg) of about 25 g/10 min to about 80 g/10 min, and a melt index ratio of about 10 to about 50.
    Type: Application
    Filed: October 4, 2022
    Publication date: December 5, 2024
    Inventors: Nino RUOCCO, Maria Josefina CARBONE, Etienne RH LERNOUX, Michael A. LEAF, Wen LI, Adriana S. SILVA
  • Publication number: 20240400805
    Abstract: Provided herein are polymer compositions comprising a polymer and polymer processing aid (PPA) comprising a blend of at least two of: (i) a polyethylene glycol; (ii) a surfactant comprising a sorbitan ester or a polysorbate; and (iii) a metal salt of a fatty acid. The polymer can be a C2-C6 olefin homopolymer or a copolymer of two or more C2-C20 ?-olefins. and the polymer composition can take the form of polymer pellets; a polymer melt; reactor-grade polymer granules and/or polymer slurries; or other form of polymer composition containing the PPA and optionally one or more other additives. The polymer composition is preferably free or substantially free of fluorine, including fluoropolymer-based PPAs.
    Type: Application
    Filed: September 22, 2022
    Publication date: December 5, 2024
    Inventors: Michael A. LEAF, Danny VAN HOYWEGHEN, Nino RUOCCO
  • Publication number: 20240392129
    Abstract: Provided herein are polymer compositions comprising a Ziegler Natta-catalyzed polymer and polymer processing aid (PPA) compositions. The PPA composition comprises a polyethylene glycol, and optionally a sorbitan ester or polysorbate. The polyethylene glycol can have molecular weight less than 40,000 g/mol. The polymer can have melt index ratio (MIR) of 20 or greater. The polymer composition is preferably free or substantially free of fluorine, including fluoropolymer-based PPAs.
    Type: Application
    Filed: September 27, 2022
    Publication date: November 28, 2024
    Inventors: Nino RUOCCO, Michael A. LEAF, Danny VAN HOYWEGHEN
  • Publication number: 20240392121
    Abstract: Provided herein are polymer compositions comprising a polymer and a surfactant. The surfactant can serve as a polymer processing aid (PPA), and can include a sorbitan ester and/or a polysorbate, preferably a polysorbate. The polymer composition can optionally include other additives, as well. The polymer can be a C2-Ce olefin homopolymer or a copolymer of two or more C2-C20 a-olefins, and the polymer composition can take the form of polymer pellets; a polymer melt; reactor-grade polymer granules and/or polymer slurries; or other form of polymer composition containing the PPA and optionally one or more other additives. The polymer composition is preferably free or substantially free of fluorine, including fluoropoly mer-based PPAs.
    Type: Application
    Filed: September 22, 2022
    Publication date: November 28, 2024
    Inventors: Danny VAN HOYWEGHEN, Michael A. LEAF
  • Publication number: 20240392120
    Abstract: Provided herein are polymer compositions comprising a polymer and polyethylene glycol (PEG)-based polymer processing aid (PPA) compositions. The polyethylene glycol can have molecular weight less than 40,000 g/mol. The polymer can be a C2-C6 olefin homopolymer or a copolymer of two or more C2-C20 ?-olefins, and can have melt index ratio (MIR) of 20 or less. The polymer composition can further include a metal salt of a fatty acid. The polymer composition is preferably free or substantially free of fluorine, including fluoropolymer-based PPAs.
    Type: Application
    Filed: September 22, 2022
    Publication date: November 28, 2024
    Inventors: Nino RUOCCO, Michael A. LEAF, Danny VAN HOYWEGHEN
  • Patent number: 12018142
    Abstract: Provided herein are polymer compositions comprising a polymer and polyethylene glycol (PEG)-based polymer processing aid (PPA). The polyethylene glycol can have molecular weight less than 40,000 g/mol. The polymer can be a C2-C6 olefin homopolymer or a copolymer of two or more C2-C20 ?-olefins, and the polymer composition can take the form of polymer pellets; a polymer melt; reactor-grade polymer granules and/or polymer slurries; or other form of polymer composition containing the PPA and optionally one or more other additives. The polymer composition is preferably free or substantially free of fluorine, including fluoropolymer-based PPAs.
    Type: Grant
    Filed: September 23, 2022
    Date of Patent: June 25, 2024
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Michael A. Leaf, Danny Van Hoyweghen, Nino Ruocco
  • Publication number: 20230399426
    Abstract: Provided herein are metallocene-catalyzed polyethylene compositions that exhibit a high degree of broad orthogonal composition distribution (“BOCD”), meaning that they have a relatively high degree of short-chain branching in higher-molecular-weight chains, as compared to the short-chain branching in lower-molecular weight chains. The compositions may have 80 to 99.9 wt % units derived from ethylene and 0.1 to 20 wt % units derived from a C3 to C40 ?-olefin comonomer; density from 0.925 to 0.950 g/cm3, melt index (I2.16) within the range from 0.1 to 5 g/10 min, and molecular weight distribution (Mw/Mn) within the range from 4.0 to 8.0.
    Type: Application
    Filed: November 22, 2021
    Publication date: December 14, 2023
    Inventors: Wen LI, Haiqing PENG, Michael A. LEAF, Kevin A. STEVENS
  • Patent number: 11702535
    Abstract: Provided herein are polymer compositions comprising a polymer and polymer processing aid (PPA) comprising a blend of at least two of: (i) a polyethylene glycol; (ii) a surfactant comprising a sorbitan ester or a polysorbate; and (iii) a metal salt of a fatty acid. The polymer can be a C2-C6 olefin homopolymer or a copolymer of two or more C2-C20 ?-olefins, and the polymer composition can take the form of polymer pellets; a polymer melt; reactor-grade polymer granules and/or polymer slurries; or other form of polymer composition containing the PPA and optionally one or more other additives. The polymer composition is preferably free or substantially free of fluorine, including fluoropolymer-based PPAs.
    Type: Grant
    Filed: September 23, 2022
    Date of Patent: July 18, 2023
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Nino Ruocco, Michael A. Leaf, Danny Van Hoyweghen
  • Patent number: 11643534
    Abstract: Provided herein are polymer compositions and methods of making them, including blending a polymer and a polyethylene glycol (PEG) masterbatch. The PEG masterbatch can include one or more PEGs each having molecular weight less than 40,000 g/mol. The polymer can be a C2-C6 olefin homopolymer or a copolymer of two or more C2-C20 ?-olefins. The PEG masterbatch and resulting polymer composition is preferably free or substantially free of fluorine, including fluoropolymer-based PPAs.
    Type: Grant
    Filed: September 23, 2022
    Date of Patent: May 9, 2023
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Nino Ruocco, Michael A. Leaf, Danny Van Hoyweghen
  • Publication number: 20230036922
    Abstract: Provided herein are polymer compositions comprising a polymer and polyethylene glycol (PEG)-based polymer processing aid (PPA). The polyethylene glycol can have molecular weight less than 40,000 g/mol. The polymer can be a C2-C6 olefin homopolymer or a copolymer of two or more C2-C20 ?-olefins, and the polymer composition can take the form of polymer pellets; a polymer melt; reactor-grade polymer granules and/or polymer slurries; or other form of polymer composition containing the PPA and optionally one or more other additives. The polymer composition is preferably free or substantially free of fluorine, including fluoropolymer-based PPAs.
    Type: Application
    Filed: September 23, 2022
    Publication date: February 2, 2023
    Inventors: Michael A. LEAF, Danny Van Hoyweghen
  • Publication number: 20230031000
    Abstract: Provided herein are polymer compositions comprising a polymer and polymer processing aid (PPA) comprising a blend of at least two of: (i) a polyethylene glycol; (ii) a surfactant comprising a sorbitan ester or a polysorbate; and (iii) a metal salt of a fatty acid. The polymer can be a C2-C6 olefin homopolymer or a copolymer of two or more C2-C20 ?-olefins, and the polymer composition can take the form of polymer pellets; a polymer melt; reactor-grade polymer granules and/or polymer slurries; or other form of polymer composition containing the PPA and optionally one or more other additives. The polymer composition is preferably free or substantially free of fluorine, including fluoropolymer-based PPAs.
    Type: Application
    Filed: September 23, 2022
    Publication date: February 2, 2023
    Inventors: Nino RUOCCO, Michael A. LEAF, Danny VAN HOYWEFHEN
  • Publication number: 20230024578
    Abstract: Provided herein are polymer compositions and methods of making them, including blending a polymer and a polyethylene glycol (PEG) masterbatch. The PEG masterbatch can include one or more PEGs each having molecular weight less than 40,000 g/mol. The polymer can be a C2-C6 olefin homopolymer or a copolymer of two or more C2-C20 ?-olefins. The PEG masterbatch and resulting polymer composition is preferably free or substantially free of fluorine, including fluoropolymer-based PPAs.
    Type: Application
    Filed: September 23, 2022
    Publication date: January 26, 2023
    Inventors: Nino RUOCCO, Michael A. LEAF, Danny VAN HOYWEGHEN