Patents by Inventor Phillip T. Matsunaga

Phillip T. Matsunaga 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: 10385198
    Abstract: Provided herein are metallocene-catalyzed polymer compositions that exhibit advantageous rheological properties, at least some of which are consistent with long-chain branching, as well as polymerization processes suitable for forming such polymer compositions. The polymer compositions may have both LCB index measured at 125° C. of less than 5; and phase angle ? at complex shear modulus G*=100,000 Pa of less than about 54.5°, as determined at 125° C. The polymer compositions of particular embodiments are reactor blends, preferably of ethylene copolymers (e.g., ethylene-propylene (EP) copolymers and/or ethylene-propylene-diene (EPDM) terpolymers). The reactor blend may include first and second copolymer components, which may differ in monomer content and weight-average molecular weight (Mw).
    Type: Grant
    Filed: December 28, 2015
    Date of Patent: August 20, 2019
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Jo Ann M. Canich, Rainer Kolb, Periagaram S. Ravishankar, Phillip T. Matsunaga, Peijun Jiang, Rhutesh K. Shah, Narayanaswami Dharmarajan
  • Publication number: 20190169413
    Abstract: Provided herein are polymerization processes and polymer compositions including reactor blends formed by such polymerization processes. The polymerization processes include copolymerization using two metallocene catalyst systems: the first catalyst system capable of producing polymers having 60% or more vinyl terminations, the second catalyst system capable of producing high molecular weight polymers, preferably incorporating at least some of the polymers produced by the first catalyst system into the high molecular weight polymers. The reactor blends formed thereby therefore include first and second copolymer components, which may differ in monomer content and weight-average molecular weight (Mw). Furthermore, the reactor blends may exhibit advantageous rheological properties, at least some of which are consistent with long-chain branching. Preferred reactor blends comprise ethylene-propylene-diene (EPDM) terpolymers.
    Type: Application
    Filed: February 4, 2019
    Publication date: June 6, 2019
    Inventors: Jo Ann M. Canich, Rainer Kolb, Periagaram S. Ravishankar, Phillip T. Matsunaga, Peijun Jiang, Rhutesh K. Shah, Narayanaswami Dharmarajan
  • Patent number: 10253173
    Abstract: Provided herein are polymerization processes and polymer compositions including reactor blends formed by such polymerization processes. The polymerization processes include copolymerization using two metallocene catalyst systems: the first catalyst system capable of producing polymers having 60% or more vinyl terminations, the second catalyst system capable of producing high molecular weight polymers, preferably incorporating at least some of the polymers produced by the first catalyst system into the high molecular weight polymers. The reactor blends formed thereby therefore include first and second copolymer components, which may differ in monomer content and weight-average molecular weight (Mw). Furthermore, the reactor blends may exhibit advantageous rheological properties, at least some of which are consistent with long-chain branching. Preferred reactor blends comprise ethylene-propylene-diene (EPDM) terpolymers.
    Type: Grant
    Filed: December 28, 2015
    Date of Patent: April 9, 2019
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Jo Ann M. Canich, Rainer Kolb, Periagaram S. Ravishankar, Phillip T. Matsunaga, Peijun Jiang, Rhutesh K. Shah, Narayanaswami Dharmarajan
  • Publication number: 20180327524
    Abstract: A catalyst system including two or more metallocene catalysts and processes for using the same to produce polyolefin polymer compositions are provided. The polyolefin polymer compositions have a good balance of a melt index ratio and normalized melt strength.
    Type: Application
    Filed: April 11, 2018
    Publication date: November 15, 2018
    Inventors: Ching-Tai Lue, Phillip T. Matsunaga, Donna J. Crowther
  • Publication number: 20180171049
    Abstract: Methods for making a high density polyethylene composition are provided. The methods can include contacting ethylene and at least one non-ethylene comonomer with a catalyst system in a gas phase reactor in the presence of hydrogen at an ethylene partial pressure of 100 psi or more to produce a polyethylene copolymer. In one or more embodiments, the catalyst system can include one or more bis amides. The resulting polyethylene copolymer can have a density of about 0.945 g/cm3 or more; a melt index (I2) of about 5 dg/min to about 50 dg/min; a melt index ratio (I21/I2) of about 20 to about 35; and a molecular weight distribution of about 3.0 to about 10.
    Type: Application
    Filed: November 8, 2017
    Publication date: June 21, 2018
    Inventors: Ching-Tai Lue, Phillip T. Matsunaga, David H. McConville, Tae Hoon Kwalk
  • Publication number: 20180155459
    Abstract: Borate activated catalyst systems and methods for making the same for gas phase or slurry phase olefin polymerization are provided. The catalyst system can include a first catalyst comprising a borate activated mono cyclopentadienyl metallocene compound and a second catalyst comprising a supported bis cyclopentadienyl metallocene complex. A supported bis cyclopentadienyl metallocene complex can be prepared to provide a preformed, supported catalyst, wherein the supported bis cyclopentadienyl metallocene complex comprises bis(1,3-methylbutyl cyclopentadienyl) zirconium dichloride. The preformed, supported catalyst can be mixed with mineral oil or hydrocarbon solvent to form a slurry. The slurry can be mixed with a borate activated mono cyclopentadienyl metallocene compound to form the borate activated catalyst system.
    Type: Application
    Filed: November 6, 2017
    Publication date: June 7, 2018
    Inventors: Dongming Li, Ching-Tai Lue, Phillip T. Matsunaga, Mark B. Davis
  • Publication number: 20180002516
    Abstract: Provided herein are polymerization processes and polymer compositions including reactor blends formed by such polymerization processes. The polymerization processes include copolymerization using two metallocene catalyst systems: the first catalyst system capable of producing polymers having 60% or more vinyl terminations, the second catalyst system capable of producing high molecular weight polymers, preferably incorporating at least some of the polymers produced by the first catalyst system into the high molecular weight polymers. The reactor blends formed thereby therefore include first and second copolymer components, which may differ in monomer content and weight-average molecular weight (Mw). Furthermore, the reactor blends may exhibit advantageous rheological properties, at least some of which are consistent with long-chain branching. Preferred reactor blends comprise ethylene-propylene-diene (EPDM) terpolymers.
    Type: Application
    Filed: December 28, 2015
    Publication date: January 4, 2018
    Inventors: Jo Ann M. Canich, Rainer Kolb, Periagaram S. Ravishankar, Phillip T. Matsunaga, Peijun Jiang, Rhutesh K. Shah, Narayanaswami Dharmarajan
  • Publication number: 20180002517
    Abstract: Provided herein are metallocene-catalyzed polymer compositions that exhibit advantageous rheological properties, at least some of which are consistent with long-chain branching, as well as polymerization processes suitable for forming such polymer compositions. The polymer compositions may have both LCB index measured at 125° C. of less than 5; and phase angle ? at complex shear modulus G*=100,000 Pa of less than about 54.5°, as determined at 125° C. The polymer compositions of particular embodiments are reactor blends, preferably of ethylene copolymers (e.g., ethylene-propylene (EP) copolymers and/or ethylene-propylene-diene (EPDM) terpolymers). The reactor blend may include first and second copolymer components, which may differ in monomer content and weight-average molecular weight (Mw).
    Type: Application
    Filed: December 28, 2015
    Publication date: January 4, 2018
    Inventors: Jo Ann M. Canich, Rainer Kolb, Periagaram S. Ravishankar, Phillip T. Matsunaga, Peijun Jiang, Rhutesh K. Shah, Narayanaswami Dharmarajan
  • Publication number: 20170362350
    Abstract: Processes are provided which include copolymerization using one or both of a metallocene catalyst capable of producing high molecular weight polymers and a metallocene catalyst capable of producing polymers having 60% or more vinyl terminations. Polymerization processes include dual catalyst polymerization in a single polymerization zone comprising both metallocene catalysts. Other processes include serial or parallel polymerizations in multiple polymerization zones, using either or both catalysts in each polymerization zone. Such polymerization processes produce reactor blends, and are particularly suited for producing copolymer compositions (such as EP or EPDM copolymer compositions) exhibiting improved melt elasticity and rheological properties.
    Type: Application
    Filed: December 28, 2015
    Publication date: December 21, 2017
    Inventors: Jo Ann M. Canich, Rainer Kolb, Periagaram S. Ravishankar, Phillip T. Matsunaga, Peijun Jiang, Rhutesh K. Shah, Narayanaswami Dharmarajan
  • Patent number: 9796645
    Abstract: This invention is directed to a poly alpha olefin (PAO) composition formed in a first oligomerization, wherein at least portions of the PAO have properties that make them highly desirable for a subsequent oligomerization. A preferred process for producing this PAO uses a single site catalyst at high temperatures without adding hydrogen to produce a low viscosity PAO with excellent Noack volatility at high conversion rates. This PAO comprises a dimer product with at least 25 wt % tri-substituted vinylene olefins wherein said dimer product is highly desirable as a feedstock for a subsequent oligomerization. This PAO also comprises trimer and optionally higher oligomer products with outstanding properties that make these products useful as lubricant basestocks following hydrogenation.
    Type: Grant
    Filed: September 12, 2012
    Date of Patent: October 24, 2017
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Craig J. Emett, Mark P. Hagemeister, Wenning W. Han, Bruce A. Harrington, Phillip T. Matsunaga, Charles J. Ruff, Kevin B. Stavens, Margaret M. Wu
  • Patent number: 9399746
    Abstract: Poly alpha olefins (PAOs) are characterized by very low viscosity and excellent Noack volatility. A preferred process for synthesizing said PAOs involves first oligomerizing low molecular weight linear alpha olefins in the presence of a single site catalyst at high temperatures without adding hydrogen and then subsequently oligomerizing at least a portion of the product from the first step in the presence of an oligomerization catalyst.
    Type: Grant
    Filed: September 12, 2012
    Date of Patent: July 26, 2016
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Craig J. Emett, Mark P. Hagemeister, Bruce A. Harrington, Phillip T. Matsunaga, Pramod J. Nandapurkar, Charles J. Ruff, Kevin B. Stavens
  • Patent number: 9365788
    Abstract: This invention is directed to a two-step process for the preparation of improved poly alpha olefins wherein the first step involves oligomerizing low molecular weight linear alpha olefins in the presence of a single site catalyst and the second step involves oligomerization of at least a portion of the product from the first step in the presence of an oligomerization catalyst. The dimer product from the first oligomerization is characterized by a tri-substituted vinylene olefin content of at least 25 wt %.
    Type: Grant
    Filed: September 12, 2012
    Date of Patent: June 14, 2016
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Craig J. Emett, Mark P. Hagemeister, Bruce A. Harrington, Chon Y. Lin, Phillip T. Matsunaga, Charles J. Ruff, Kevin B. Stavens
  • Patent number: 9359535
    Abstract: A multi-modal polymer blend for use in an adhesive composition comprising at least two compositionally different propylene-based polymers. The multi-modal polymer blend has a Mw of about 10,000 g/mol to about 150,000 g/mol. When subjected to Temperature Rising Elution Fractionation, the multi-modal polymer blend exhibits a first fraction that is soluble at ?15° C. in a hydrocarbon solvent, such as xylene or ortho-dichlorobenzene, the first fraction having an isotactic (mm) triad tacticity of about 70 mol % to about 90 mol %; and a second fraction that is insoluble or less soluble than the first fraction at ?15° C. in the hydrocarbon solvent, the second fraction having an isotactic (mm) triad tacticity of about 85 mol % to about 98 mol %.
    Type: Grant
    Filed: February 28, 2013
    Date of Patent: June 7, 2016
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: James N. Coffey, George Rodriguez, Phillip T. Matsunaga, Mun Fu Tse, Shawn W. Mowry, Jean-Roch H. Schauder, Yann Devorest, Jurgen J. M. Schroeyers, Joseph M. DeLucia
  • Publication number: 20150322303
    Abstract: A multi-modal polymer blend for use in an adhesive composition comprising at least two compositionally different propylene-based polymers. The multi-modal polymer blend has a Mw of about 10,000 g/mol to about 150,000 g/mol. When subjected to Temperature Rising Elution Fractionation, the multi-modal polymer blend exhibits a first fraction that is soluble at ?15° C. in a hydrocarbon solvent, such as xylene or ortho-dichlorobenzene, the first fraction having an isotactic (mm) triad tacticity of about 70 mol % to about 90 mol %; and a second fraction that is insoluble or less soluble than the first fraction at ?15° C. in the hydrocarbon solvent, the second fraction having an isotactic (mm) triad tacticity of about 85 mol % to about 98 mol %.
    Type: Application
    Filed: February 28, 2013
    Publication date: November 12, 2015
    Inventors: James N. Coffey, George Rodriguez, Phillip T. Matsunaga, Mun Fu Tse, Shawn W. Mowry, Jean-Roch H. Schauder, Yann Devorest, Jurgen J.M. Schroeyers, Joseph M. DeLucia
  • Patent number: 9139794
    Abstract: Provided are processes for making polymer compositions, especially those with reduced or no gel formation in lubricating oils as identified by rheological and visual gel tests and which are useful as viscosity modifiers. The processes described herein aim to achieve this objective by adjusting the concentrations of the hydrogen feed(s) in the first and/or second polymerization reaction zones, preferably such that (a) the hydrogen feed concentration in the first polymerization reaction zone is 0.0-1.0 wt %, based on total weight of feed(s) of hydrogen, ethylene monomer, ?-olefin comonomer, and solvent into the first polymerization reaction zone, and/or (b) the hydrogen feed concentration in the second polymerization reaction zone is 0.0-0.5 wt %, based on total weight of feed(s) of hydrogen, ethylene monomer, ?-olefin comonomer, and solvent into the second polymerization reaction zone.
    Type: Grant
    Filed: February 3, 2012
    Date of Patent: September 22, 2015
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Rainer Kolb, Phillip T. Matsunaga, Periagaram S. Ravishankar, Lisa B. Stefaniak, Quintin Paul Ward Costin
  • Patent number: 9127151
    Abstract: Polymer compositions for use as viscosity modifiers comprising at least two ethylene-based copolymer components are provided. The polymer composition comprises (a) a first ethylene-?-olefin copolymer and (b) a second ethylene-?-olefin copolymer. The first ethylene-?-olefin copolymer (a) has an ethylene content from about 60 to about 80 wt % and the second ethylene-?-olefin copolymer (b) has an ethylene content of less than about 60 wt %. The first ethylene-?-olefin copolymer (a) has a Melt Flow Rate Ratio (MFRR), defined as the ratio of the MFR measured at 230° C./21.6 kg and at 230° C./2.16 kg, of greater than 30 and optionally also has a Melt Flow Rate (MFR) of at least about 1.5 g/10 min, measured by ASTM D 1238 condition L (230° C./2.16 kg). The present disclosure is also directed to lubricant compositions comprising a lubricating basestock and a polymer composition of the present disclosure and is further directed to reducing gelation in the lubricant compositions.
    Type: Grant
    Filed: February 3, 2012
    Date of Patent: September 8, 2015
    Assignees: ExxonMobil Chemical Patents Inc., Chevron Oronite Company LLC
    Inventors: Phillip T. Matsunaga, Kirk A. Nass, Pritesh A. Patel, Rainer Kolb, Sudhin Datta
  • Patent number: 8664461
    Abstract: This invention is directed to new mono-cyclopentadienyl (“mono-Cp”) metallocene catalyst compounds useful for producing high viscosity PAOs with narrow molecular weight distribution and good shear stability. Specifically, this invention relates to a group of bridged mono-Cp catalysts wherein, in an embodiment of the invention, the aromatic ring structure is substituted with: 1) at least one phenyl group, 2) at least one alkyl group, and 3) at least one other group, such as a hydrocarbyl group, a heteroatom, or a heteroatom-containing group.
    Type: Grant
    Filed: March 19, 2012
    Date of Patent: March 4, 2014
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Bruce A. Harrington, Abhimanyu O. Patil, Donna J. Crowther, Phillip T. Matsunaga, Kevin B. Stavens, Catalina L. Coker
  • Publication number: 20130253244
    Abstract: This invention is directed to a two-step process for the preparation of improved poly alpha olefins wherein the first step involves oligomerizing low molecular weight linear alpha olefins in the presence of a single site catalyst and the second step involves oligomerization of at least a portion of the product from the first step in the presence of an oligomerization catalyst. The dimer product from the first oligomerization is characterized by a tri-substituted vinylene olefin content of at least 25 wt %.
    Type: Application
    Filed: September 12, 2012
    Publication date: September 26, 2013
    Inventors: Craig J. Emett, Mark P. Hagemeister, Bruce A. Harrington, Chon Y. Lin, Phillip T. Matsunaga, Charles J. Ruff, Kevin B. Stavens
  • Publication number: 20130245213
    Abstract: This invention is directed to new mono-cyclopentadienyl (“mono-Cp”) metallocene catalyst compounds useful for producing high viscosity PAOs with narrow molecular weight distribution and good shear stability. Specifically, this invention relates to a group of bridged mono-Cp catalysts wherein, in an embodiment of the invention, the aromatic ring structure is substituted with: 1) at least one phenyl group, 2) at least one alkyl group, and 3) at least one other group, such as a hydrocarbyl group, a heteroatom, or a heteroatom-containing group.
    Type: Application
    Filed: March 19, 2012
    Publication date: September 19, 2013
    Inventors: Bruce A. Harrington, Abhimanyu O. Patil, Donna J. Crowther, Phillip T. Matsunaga, Kevin B. Stavens, Catalina L. Coker
  • Publication number: 20130245343
    Abstract: This invention is directed to a poly alpha olefin (PAO) composition formed in a first oligomerization, wherein at least portions of the PAO have properties that make them highly desirable for a subsequent oligomerization. A preferred process for producing this PAO uses a single site catalyst at high temperatures without adding hydrogen to produce a low viscosity PAO with excellent Noack volatility at high conversion rates. This PAO comprises a dimer product with at least 25 wt % tri-substituted vinylene olefins wherein said dimer product is highly desirable as a feedstock for a subsequent oligomerization. This PAO also comprises trimer and optionally higher oligomer products with outstanding properties that make these products useful as lubricant basestocks following hydrogenation.
    Type: Application
    Filed: September 12, 2012
    Publication date: September 19, 2013
    Inventors: Craig J. Emett, Mark P. Hagemeister, Wenning W. Han, Bruce A. Harrington, Phillip T. Matsunaga, Charles J. Ruff, Kevin B. Stavens, Margaret M. Wu