Abstract: Polyethylene copolymers with a structure that provides improved film properties are provided. The copolymers can have a density of about 0.905 to about 0.911 g/cm3. The copolymers can also have a DRI/I2 ratio of about 0.0008 to about 0.060, an I2 value of about 0.6 to about 3.8 dg/min, and an I21 value of about 8 to about 57 dg/min. The copolymers having those properties can be produced by introducing ethylene and at least one other olefin comonomer to a single reactor at a comonomer/ethylene mole ratio of about 0.02 to about 0.03 and polymerizing at a temperature of about 76.7° C. to about 80.6° C. and a pressure of about 1,724 kPa to about 2,413 kPa. The copolymers can be used to make films having a 21 mol % O2 transmission rate of about 150 to about 200 cc/100 in2/24 hr. and hot tack seal initiation temperatures of about 65° C. to 80° C.

Abstract: Provided are polyethylene copolymers with improved stress crack resistance, methods for making such copolymers, and films made from the same. The polyethylene copolymers include at least 95 wt % ethylene and at most 5 wt % of at least one comonomer having 3 to 18 carbon atoms; and further have a 30% single point notched constant tensile load of at least 1,000 hours, a density of 0.931 to 0.936 g/cm3, a melt index (I2) of 0.1 to 0.5 g/10 min, and a 25-75 chemical composition distribution index of 0.3 or more.

Abstract: Foam pellets comprising a thermoplastic vulcanizate (TPV) and thermo-expandable microspheres, the foam pellet having a specific gravity of 0.2 to 1.0 and the TPV being composed of an at least partially vulcanized rubber component and a thermoplastic component. The foam pellets may be subsequently processed to form various foam articles without the need to include a foaming agent during processing.

Abstract: The present disclosure relates to TPV compositions suitable for foaming, as well as foamed TPV compositions, methods of making the foregoing, and applications of various foamed TPV compositions. The TPV compositions comprise an at least partially vulcanized rubber component dispersed within a thermoplastic component comprising a thermoplastic resin and a propylene-based elastomer, oil, and optionally one or more additives. According to some aspects, the TPV composition may be made in part by preloading some portion of process oil prior to addition of the curative. TPV compositions provided herein are particularly suitable for foaming with thermo-expandable microsphere foaming agents.

Abstract: A cast film is made from at least one ethylene polymer which comprises from 75.0 mol % to 100.0 mol % of ethylene derived units and which has a density of from 0.900 g/cm3 to 0.926 g/cm3, a melt index (I2.16) from greater than 1.2 g/10 min to 6 g/10 min, a melt index ratio (I21.6/I2.16) of from 20 to 50, and a z-average molecular weight (Mz) of greater 150,000 g/mol. The cast film has an average flex crack resistance as measured by ASTM F392 of less than or equal to 15 holes/300 cm2 after 10,000 cycles, preferably 8±1 holes/300 cm2 after 10,000 cycles.

Abstract: The present disclosure relates to processes for producing a catalyst composition. A process may include mixing a catalyst compound having a transition metal atom, an activator, and a support to form a supported catalyst mixture. A process may also include drying the supported catalyst mixture at a pressure of about 10 kPa or less and a temperature of about 60° C. or greater for a period of about 6 h or less. The present disclosure also relates to processes for producing polyolefins. A process may include introducing a catalyst composition and at least one olefin to a polymerization reactor, where the catalyst composition has about 0.5 wt % to about 1.5 wt % aromatic hydrocarbon content, and less than 1 wt % of aliphatic hydrocarbon content. A process may also include obtaining a polyolefin having about 300 ppb or less aromatic hydrocarbon.

Abstract: Polyethylene copolymers with a structure that provides improved film properties are provided. The copolymers can have a density of about 0.905 to about 0.911 g/cm3. The copolymers can also have a DRI/I2 ratio of about 0.0008 to about 0.060, an I2 value of about 0.6 to about 3.8 dg/min, and an I21 value of about 8 to about 57 dg/min. The copolymers having those properties can be produced by introducing ethylene and at least one other olefin comonomer to a single reactor at a comonomer/ethylene mole ratio of about 0.02 to about 0.03 and polymerizing at a temperature of about 76.7° C. to about 80.6° C. and a pressure of about 1,724 kPa to about 2,413 kPa. The copolymers can be used to make films having a 21 mol % O2 transmission rate of about 150 to about 200 cc/100 in2/24 hr. and hot tack seal initiation temperatures of about 65° C. to 80° C.

Abstract: Provided are methods for producing a thermoplastic vulcanizate and thermoplastic vulcanizates provided therein. The method includes introducing vulcanizable rubber, thermoplastic resin, a masterbatch of a propylene-based elastomer and a cure accelerator for a phenolic resin curative to the reactor, and phenolic resin curative to a reactor and dynamically vulcanizing the rubber with the phenolic resin curative in the presence of the cure accelerator and the thermoplastic resin.

Abstract: A process for producing a thermoplastic vulcanizate, the process comprising: (i) charging a reactor with an oil-extended olefinic copolymer rubber, where the rubber is synthesized by a single-site catalyst, characterized by a multi-modal molecular weight distribution, and includes greater than 10 parts by weight extender oil per 100 parts by weight rubber; (ii) charging the reactor, contemporaneously or sequentially with respect to the rubber, with a thermoplastic resin, an oil, and a cure system to provide a pre-vulcanized mixture; and (iii) mixing the rubber, thermoplastic resin, oil, and cure system at a temperature above the melt temperature of the thermoplastic resin to thereby cause dynamic vulcanization of the rubber and produce the thermoplastic vulcanizate.

Abstract: The present disclosure relates to thermoplastic vulcanizate (TPV) compositions and foaming agent masterbatches suitable for foaming, as well as foamed TPV compositions, methods of making the foregoing, and applications of various foamed TPV compositions. In particular, the present disclosure provides foaming agent masterbatches having unconventionally lower loading of foaming agent in carrier polymer. The carrier polymer may advantageously comprise or be a plastomer and/or propylene-based elastomer that is also suitable for inclusion in the TPV composition, and foaming the TPV composition may include the use of relatively greater amounts of foaming agent masterbatch. The use of greater amounts of foaming agent masterbatch with lower loading may allow for superior distribution of the foaming agent in the TPV composition during foaming, leading to greater uniformity of extent of foaming (e.g., as may be shown through greater uniformity of specific gravity in the foamed TPV composition).

Abstract: The present disclosure relates to TPV compositions suitable for foaming, as well as foamed TPV compositions, methods of making the foregoing, and applications of various foamed TPV compositions. The TPV compositions comprise an at least partially vulcanized rubber component dispersed within a thermoplastic component comprising a thermoplastic resin and a propylene-based elastomer, oil, and optionally one or more additives. According to some aspects, the TPV composition may be made in part by preloading some portion of process oil prior to addition of the curative. TPV compositions provided herein are particularly suitable for foaming with thermo-expandable microsphere foaming agents.

Abstract: Provided are methods of making thermoplastic vulcanizates and thermoplastic vulcanizates made therefrom. The methods can comprise adding vulcanizable elastomer to a reactor; adding a masterbatch comprising a thermoplastic resin and a metal oxide to the reactor; adding a curative to the reactor; and dynamically vulcanizing the elastomer.

Abstract: Provided herein are thermoplastic vulcanizates that comprise rubber, broad molecular weight distribution polypropylene, and oil, where the rubber forms a rubber phase that is dispersed and at least partially cross-linked within a continuous thermoplastic component that comprises the broad molecular weight distribution polypropylene. The broad molecular weight distribution polypropylene preferably has a molecular weight distribution (Mw/Mn) of greater than 4; a melt flow rate of greater than 1 g/10 min; and a weight average molecular weight (Mw) of greater than 380,000 daltons.

Abstract: The present disclosure relates to a method for making thermoplastic vulcanizates comprising dynamically vulcanizing an elastomer in an extrusion reactor with a curative in the presence of a thermoplastic resin to form a thermoplastic vulcanizate. Process oil is added to the extrusion reactor at a first, second, and third location, where the amount of process oil introduced at the first oil injection location is less than that introduced at the second oil injection location, where the third oil injection location is downstream of where the curative is introduced to the extrusion reactor, and where the thermoplastic vulcanizate comprises at least 25 wt % of oil based on the weight of the thermoplastic vulcanizate.

Abstract: Described herein are thermoplastic vulcanizates comprising propylene-based elastomers and methods for producing the same. The thermoplastic vulcanizates comprise rubber, at least 10 wt % of thermoplastic resin, from 1 to 9 wt % of propylene-based elastomer, oil, and at least 5 wt % of one or more fillers. The thermoplastic vulcanizates are made by a method where the propylene-based elastomer is introduced to the extrusion reactor before the curative is introduced to the extrusion reactor.

Abstract: A process for producing a thermoplastic vulcanizate, the process comprising: (i) charging a reactor with an oil-extended olefinic copolymer rubber, where the rubber is synthesized by a single-site catalyst, characterized by a multi-modal molecular weight distribution, and includes greater than 10 parts by weight extender oil per 100 parts by weight rubber; (ii) charging the reactor, contemporaneously or sequentially with respect to the rubber, with a thermoplastic resin, an oil, and a cure system to provide a pre-vulcanized mixture; and (iii) mixing the rubber, thermoplastic resin, oil, and cure system at a temperature above the melt temperature of the thermoplastic resin to thereby cause dynamic vulcanization of the rubber and produce the thermoplastic vulcanizate.

Abstract: Provided are methods of making thermoplastic vulcanizates and thermoplastic vulcanizates made therefrom. The methods can comprise adding vulcanizable elastomer to a reactor; adding a masterbatch comprising a thermoplastic resin and a metal oxide to the reactor; adding a curative to the reactor; and dynamically vulcanizing the elastomer.

Abstract: The present disclosure relates to thermoplastic vulcanizate (TPV) compositions and foaming agent masterbatches suitable for foaming, as well as foamed TPV compositions, methods of making the foregoing, and applications of various foamed TPV compositions. In particular, the present disclosure provides foaming agent masterbatches having unconventionally lower loading of foaming agent in carrier polymer. The carrier polymer may advantageously comprise or be a plastomer and/or propylene-based elastomer that is also suitable for inclusion in the TPV composition, and foaming the TPV composition may include the use of relatively greater amounts of foaming agent masterbatch. The use of greater amounts of foaming agent masterbatch with lower loading may allow for superior distribution of the foaming agent in the TPV composition during foaming, leading to greater uniformity of extent of foaming (e.g., as may be shown through greater uniformity of specific gravity in the foamed TPV composition).

Abstract: The present disclosure relates to a method for making thermoplastic vulcanizates comprising dynamically vulcanizing an elastomer in an extrusion reactor with a curative in the presence of a thermoplastic resin to form a thermoplastic vulcanizate. Process oil is added to the extrusion reactor at a first, second, and third location, where the amount of process oil introduced at the first oil injection location is less than that introduced at the second oil injection location, where the third oil injection location is downstream of where the curative is introduced to the extrusion reactor, and where the thermoplastic vulcanizate comprises at least 25 wt % of oil based on the weight of the thermoplastic vulcanizate.

Abstract: Provided are methods for producing a thermoplastic vulcanizate and thermoplastic vulcanizates provided therein. The method includes introducing vulcanizable rubber, thermoplastic resin, a masterbatch of a propylene-based elastomer and a cure accelerator for a phenolic resin curative to the reactor, and phenolic resin curative to a reactor and dynamically vulcanizing the rubber with the phenolic resin curative in the presence of the cure accelerator and the thermoplastic resin.