Abstract: Disclosed is a thermoplastic polyolefin composition useful in automotive components comprising at least a polypropylene having a melting point temperature (Tm) of greater than 130° C. and a melt flow rate (230° C./2.16 kg) within the range from 10 g/10 min to 80 g/10 min; an amorphous ethylene-propylene copolymer comprising within the range from 40 wt % to 80 wt % ethylene derived units and having a melt flow rate (230° C./2.16 kg) within the range from 0.1 g/10 min to 20 g/10 min; and a propylene-based elastomer having within the range from 5 to 25 wt % ethylene derived units and having a Tm of less than 110° C. The composition only partially breaks or there is no break at ?29° C. (ASTM D256) with Notched Izod Force of between 10 to 40 ft-lb/in2 at 22° C. (533 to 2,132 J/m2), and between 1.0 to 12 ft-lb/in2 at ?29° C. (53 to 636 J/m2).

Abstract: Methods for the production of heterophasic polymers in gas and slurry phase polymerization processes, and polymer compositions made therefrom, are disclosed herein.

Abstract: Disclosed is a thermoplastic polyolefin composition useful in automotive components comprising at least a polypropylene having a melting point temperature (Tm) of greater than 130° C. and a melt flow rate (230° C./2.16 kg) within the range from 10 g/10 min to 80 g/10 min; an amorphous ethylene-propylene copolymer comprising within the range from 40 wt % to 80 wt % ethylene derived units and having a melt flow rate (230° C./2.16 kg) within the range from 0.1 g/10 min to 20 g/10 min; and a propylene-based elastomer having within the range from 5 to 25 wt % ethylene derived units and having a Tm of less than 110° C. The composition only partially breaks or there is no break at ?29° C. (ASTM D256) with Notched Izod Force of between 10 to 40 ft-lb/in2 at 22° C. (533 to 2,132 J/m2), and between 1.0 to 12 ft-lb/in2 at ?29° C. (53 to 636 J/m2).

Abstract: Methods for the production of heterophasic polymers in gas and slurry phase polymerization processes, and polymer compositions made therefrom, are disclosed herein.

Abstract: Pellet-stable olefinic copolymer bimodal rubber is made using parallel reactors, with one reactor synthesizing higher molecular weight (MW) rubber with dual catalysts, with an improved molecular weight split ratio and an improved composition distribution of the moderate and ultra-high MW components, while another reactor synthesizes random isotactic polypropylene copolymer (RCP). The effluents are reactor-blended and result in pellet-stable bimodal rubber (P-SBR), which may be pelletized. When making thermoplastic vulcanizates (TPVs) with P-SBR, the need to granulate rubber bales and subsequently use talc, clay, or other anti-agglomeration agents to prevent granulated rubber crumbs from agglomerating are eliminated. TPVs made with P-SBR have vulcanized rubber particles that are smaller and more uniform in size, resulting in TPVs with higher particle counts and more thermoplastic “ligaments” between the particles, with such ligaments being made stronger by the added RCP.

Abstract: This invention relates to a polyolefin composition with (a) 80 to 90 wt % of an amorphous ethylene-propylene copolymer having either no crystallinity or crystallinity derived from ethylene, having about 30 wt % or more units derived from ethylene; (b) 5 to 15 wt % of a semi-crystalline ethylene-propylene copolymer having substantial crystallinity derived from ethylene and having 70 wt % or more units derived from ethylene; and (c) 1 to 5 wt % of a propylene-based elastomer having within the range from 5 to 25 wt % ethylene derived units and having a melting point temperature of less than 110° C. and a Mw/Mn within the range from 2.0 to 4.0.

Abstract: Use of twin screw extrusion to further enhance the uniformity of crosslinked rubber dispersion in thermoplastic vulcanizates (TPVs) to improve elastic properties of TPVs is disclosed. Most specifically, this invention employs intermeshing twin screw extruders to further homogenize dynamically vulcanized rubber dispersions in TPVs so that their particle size dispersion index (PSDI), or the ratio of weight average equivalent dispersion particle diameter to number average equivalent dispersion particle diameter, can be lowered to less than 1.6 or 1.57 with corresponding elastic property improvements by having lower hysteresis, higher elongation to break, and higher retractive force. TPV products having lower PSDI and improved elastic properties, and apparatus for conducting the disclosed method, are also provided.

Abstract: Disclosed is the preparation of thermoplastic vulcanizates with reduced crosslinked rubber dispersion sizes and dispersity. The thermoplastic vulcanizates include a polypropylene matrix phase in which cross-linked rubber particles are dispersed. The thermoplastic vulcanizates include the reaction product of a mixture that includes at least 10 wt % of isotactic polypropylene at least 30 wt % of an amorphous propylene-ethylene-diene terpolymer containing at least 60 wt % propylene-derived units and less than or equal to 25 wt % of ethylene-derived units; at least 10 wt % of a diluent and at least 0.015 wt % of at least one curative. The mixture is preferably formed without adding an ethylene-propylene-diene terpolymer.

Abstract: A thermoplastic vulcanizate comprises an isotactic polypropylene matrix phase in which cross-linked rubber particles are dispersed, the rubber particles comprising an ethylene-propylene-diene terpolymer (EPDM) containing at least 40 wt % of ethylene-derived units. A propylene-ethylene-diene terpolymer (PEDM) containing at least 60 wt % propylene-derived units and less than or equal to 25 wt % of ethylene-derived units and having a heat of fusion (Hf) of 2 to 10 J/g is added to compatibilize the propylene/EPDM blend.

Abstract: Disclosed is the preparation of compatibilized thermoplastic vulcanizates with reduced crosslinked rubber dispersion sizes and dispersity. A cross-linkable ethylene-propylene-diene terpolymer with majority propylene (PEDM) is used to compatibilize a plastic and rubber blend of a polypropylene (PP) and an ethylene-propylene-diene terpolymer rubber, where the propylene content is less than 50 wt % (EPDM), in dynamic vulcanization and preparation of PP/EPDM thermoplastic vulcanizates. The resulting PP/EPDM thermoplastic vulcanizates typically exhibit a weight average equivalent dispersion diameter of less than 3 microns and a particle size polydispersity index (PSDI), or weight average over number average dispersion diameter, of less than 5. This reduction in crosslinked rubber dispersion size in a PP/EPDM TPV by using PEDM compatibilizers enhances the toughness of the vulcanizate product by raising both elongation to break and break stress.

Abstract: This invention relates to a thermoplastic vulcanizate having excellent elongation comprising an isotactic polypropylene matrix phase in which a cross-linked ethylene-propylene-diene terpolymer (EPDM) is dispersed, the vulcanizate comprising the reaction product of: a) 35 to 55 wt % of an ethylene-propylene-diene terpolymer (EPDM); b) 10 to 40 wt % of isotactic polypropylene (iPP); c) 0.5 to 25 wt % of a propylene-ethylene-diene terpolymer (PEDM) compatibilizer, said compatibilizer having a heat of fusion of less than 2 J/g; and d) 0.015 to 0.03 wt % of curatives; wherein the percentages of components (a) to (d) are based on the total weight of the mixture.

Abstract: A process to produce a branched ethylene-?-olefin diene elastomer comprising combining a catalyst precursor and an activator with a feed comprising ethylene, C3 to C12 ?-olefins, and a dual-polymerizable diene to obtain a branched ethylene-?-olefin diene elastomer; where the catalyst precursor is selected from pyridyldiamide and quinolinyldiamido transition metal complexes. The branched ethylene-?-olefin diene elastomer may comprise within a range from 40 to 80 wt % of ethylene-derived units by weight of the branched ethylene-?-olefin diene elastomer, and 0.1 to 2 wt % of singly-polymerizable diene derived units, 0.1 to 2 wt % of singly-polymerizable diene derived units, and the remainder comprising C3 to C12 ?-olefin derived units, wherein the branched ethylene-?-olefin diene elastomer has a weight average molecular weight (Mw) within a range from 100 kg/mole to 300 kg/mole, an average branching index (g?avg) of 0.9 or more, and a branching index at very high Mw (g?1000) of less than 0.9.

Abstract: A process to produce a branched ethylene-?-olefin diene elastomer comprising combining a catalyst precursor and an activator with a feed comprising ethylene, C3 to C12 ?-olefins, and a dual-polymerizable diene to obtain a branched ethylene-?-olefin diene elastomer; where the catalyst precursor is selected from pyridyldiamide and quinolinyldiamido transition metal complexes. The branched ethylene-?-olefin diene elastomer may comprise within a range from 40 to 80 wt % of ethylene-derived units by weight of the branched ethylene-?-olefin diene elastomer, and 0.1 to 2 wt % of singly-polymerizable diene derived units, 0.1 to 2 wt % of singly-polymerizable diene derived units, and the remainder comprising C3 to C12 ?-olefin derived units, wherein the branched ethylene-?-olefin diene elastomer has a weight average molecular weight (Mw) within a range from 100 kg/mole to 300 kg/mole, an average branching index (g?avg) of 0.9 or more, and a branching index at very high Mw (g?1000) of less than 0.9.

Abstract: This invention relates to a thermoplastic polyolefin composition with (a) a polypropylene having a melting point of greater than 130° C. and a melt flow rate from 10 to 80 g/10 min; (b) an ethylene-propylene copolymer with 40 wt % to 80 wt % ethylene derived units and a Mooney Viscosity (1+4, 125° C.) of greater than 20 Mooney units, a Mw/Mn of from 1.8 to 4.0, and a weight average molecular weight of 50,000 to 300,000 g/mole; and (c) a propylene-based elastomer having 5 wt % to 25 wt % ethylene derived units and having a melting point of less than 110° C. and a Mw/Mn from 2.0 to 4.0; wherein the room temperature notch impact of the thermoplastic polyolefin composition is at least four times greater than the room temperature notch impact of a composition without the propylene-based elastomer.

Abstract: The present invention relates to a bimodal polypropylene composition comprising a blend of a HMW polypropylene component and a LMW polypropylene component, where the high molecular weight (HMW) component of the bimodal composition has a z-average molecular weight Mz of more than 400,000 g/mole, and a process to make such composition. The composition is suitable for thermoformed articles and injection molded articles.

Abstract: Bimodal polypropylene compositions and a process to form melt blended bimodal polypropylene compositions comprising combining at least two polypropylenes in at least a two-pass process, and forming a bimodal polypropylene composition having a Flexural Modulus (190° C., 1% secant) of at least 1700 MPa, as well as one or more other selected properties. These compositions are suitable for thermoformed articles and injection molded articles, any of which may be foamed.

Abstract: Methods for the production of heterophasic polymers in gas and slurry phase polymerization processes, and polymer compositions made therefrom, are disclosed herein.

Abstract: This invention relates to a thermoplastic polyolefin composition with (a) 45 wt % to 70 wt % of a polypropylene having 70 wt % or more units derived from propylene, having a melting point temperature of greater than 130° C. and a melt flow rate from 2 to 80 g/10 min; (b) 20 wt % to 30 wt % of a bimodal ethylene-propylene copolymer comprising: (i) 80 wt % to 90 wt % of an amorphous ethylene-propylene copolymer having about 30 wt % or more units derived from ethylene; (ii) 5 wt % to 15 wt % of a semi-crystalline ethylene-propylene copolymer having 70 wt % or more units derived from ethylene; and (iii) 1 wt % to 5 wt % of a propylene-based elastomer having within the range from 5 wt % to 25 wt % ethylene derived units and having a melting point temperature of less than 110° C. and a Mw/Mn within the range from 2.0 to 4.0.

Abstract: This invention relates to a polyolefin composition with (a) 80 to 90 wt % of an amorphous ethylene-propylene copolymer having either no crystallinity or crystallinity derived from ethylene, having about 30 wt % or more units derived from ethylene; (b) 5 to 15 wt % of a semi-crystalline ethylene-propylene copolymer having substantial crystallinity derived from ethylene and having 70 wt % or more units derived from ethylene; and (c) 1 to 5 wt % of a propylene-based elastomer having within the range from 5 to 25 wt % ethylene derived units and having a melting point temperature of less than 110° C. and a Mw/Mn within the range from 2.0 to 4.0.

Abstract: Disclosed are methods for the production of polymers, including random copolymers (RCPs), in single reactor gas or slurry phase polymerization processes, and polymer compositions produced therefrom. The methods enable polymers having low melting temperatures to be made in gas and slurry phase polymerization processes, where they conventionally could not be made in these processes due to stickiness and fouling problems in the reactor.