Patents by Inventor Todd S. Edwards
Todd S. Edwards 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).
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Patent number: 11732067Abstract: Disclosed is a polypropylene with an MFR of at least 20 g/10 min comprising a homopolypropylene and optionally within a range from 2 wt % to 30 wt % of an propylene-?-olefin copolymer by weight of the polypropylene; wherein the homopolypropylene has a MFR within a range from 30 g/10 min to 200 g/10 min, an Mw/Mn within a range from 7 to 16, and comprising 1.1 wt % or less atactic polypropylene based on the total weight of the homopolypropylene and atactic polypropylene, where the propylene-?-olefin copolymer has within a range from 30 wt % to 50 wt % ?-olefin derived units by weight of the propylene-?-olefin copolymer, and an intrinsic viscosity within a range from 4 to 8 dL/g. The impact copolymer may be obtained by combining a Ziegler-Natta catalyst having at least two different internal electron donors with propylene in reactors in series to produce the homopolypropylene followed by a gas phase reactor to produce a propylene-?-olefin copolymer.Type: GrantFiled: April 11, 2018Date of Patent: August 22, 2023Assignee: ExxonMobil Chemical Patents Inc.Inventors: Christopher G. Bauch, Todd S. Edwards
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Publication number: 20230235105Abstract: Polypropylenes and impact copolymers with low organic volatiles. The impact copolymers comprising a polypropylene and within a range from 5 wt% to 40 wt% of an ethylene-propylene copolymer or rubber, by weight of the impact copolymer; wherein the polypropylene has a melt flow rate within a range from 100 g/10 min to 400 g/10 min, and the impact copolymer has a melt flow rate within a range from 15 g/10 min to 150 g/10 min; and wherein there are less than 1000 µg of oligomer per gram of impact copolymer. The polymers may be made by combining olefins with the reaction product of a solid magnesium compound and a halogen-containing titanium compound with at least one phthalic acid ester compound and at least one diether compound as internal electron donors.Type: ApplicationFiled: July 12, 2021Publication date: July 27, 2023Applicant: EXXONMOBIL CHEMICAL PATENTS INC.Inventors: Todd S. EDWARDS, Christopher G. BAUCH, Ranadip GANGULY, Xiaodan ZHANG
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Publication number: 20230056312Abstract: Provided are methods for producing bimodal polyolefins comprising the steps of contacting ?-olefin monomers with a catalyst in slurry polymerization conditions in the presence of zero to minimum hydrogen to produce a high molecular weight polyolefin and contacting additional ?-olefin monomers in gas phase polymerization conditions and the high molecular weight polyolefin and the catalyst to produce bimodal polyolefin having high stiffness and broad molecular weight distribution. An additional step of polymerizing the bimodal polyolefin with a comonomer in a second gas phase can provide a bimodal impact copolymer having high stiffness and broad molecular weight distribution. Among the advantages of the present methods, bimodal polyolefins can be produced in a continuous process between a slurry polymerization reactor and a gas phase polymerization reactor without a venting step in between and with minimal hydrogen in the slurry polymerization reactor.Type: ApplicationFiled: January 7, 2021Publication date: February 23, 2023Applicant: ExxonMobil Chemical Patents Inc.Inventors: Xiaodan ZHANG, Christopher G. BAUCH, Todd S. EDWARDS, Mark S. CHAHL, Blu E. ENGLEHORN, Khoa TO, Steven L. LAMBERT
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Patent number: 11505685Abstract: Disclosed is a polypropylene with an MFR of at least 20 g/10 min comprising a homopolypropylene and within a range from 2 wt % to 20 wt % of a propylene-?-olefin copolymer by weight of the polypropylene, where the homopolypropylene has a MFR within a range from 30 g/10 min to 200 g/10 min, where the propylene-?-olefin copolymer comprises within a range from 30 wt % to 50 wt % ?-olefin derived units by weight of the propylene-?-olefin copolymer, and has an IV within a range from 4 to 9 dL/g. The polypropylene may be obtained by combining a Ziegler-Natta catalyst having two transition metals with propylene in reactors in series to produce the homopolypropylene followed by a gas phase reactor to produce a propylene-?-olefin copolymer blended with the homopolypropylene.Type: GrantFiled: April 11, 2018Date of Patent: November 22, 2022Assignee: ExxonMobil Chemical Patents Inc.Inventors: Todd S. Edwards, Christopher G. Bauch
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Publication number: 20220332864Abstract: Provided herein are methods of polymerizing ?-olefin monomer with a catalyst and hydrogen in a slurry to produce low molecular weight polyolefins. Hydrogen is vented from the low molecular weight polyolefins and then the low molecular weight polyolefins are further polymerized in a gas phase to produce a polyolefin having a molecular weight distribution of between 4.0 and 30 and a flexural modulus between 1500 mPa and 2500 mPa.Type: ApplicationFiled: August 14, 2020Publication date: October 20, 2022Applicant: EXXONMOBIL CHEMICAL PATENTS INC.Inventors: Xiaodan ZHANG, Christopher G. BAUCH, Lubin LUO, Jeffrey L. BRINEN, George J. PEHLERT, Todd S. EDWARDS, Sung A. KIM
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Publication number: 20210179747Abstract: A polypropylene comprising a xylene soluble fraction of 1.5 wt % by weight of the polymer and soluble fraction or less, wherein the polypropylene has a melt flow rate within a range from 50 g/10 min to 500 g/10 min and a flexural modulus within a range from 1780 MPa to 2200 MPa. The polypropylene is preferably made from contacting propylene with a solid magnesium/titanium catalyst component that has been washed at least once with a solvent having a desirable solubility parameter.Type: ApplicationFiled: August 13, 2018Publication date: June 17, 2021Inventors: Todd S. Edwards, Christopher G. Bauch
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Patent number: 10934372Abstract: A process for reducing the level of hydrogen in certain polymerization effluent and recycle streams containing unreacted propylene monomers and hydrogen by contacting the streams with a hydrogenation catalyst so as to convert at least part of the propylene to the corresponding alkane. The process is particularly applicable to the effluent from a slurry polymerization reactor which has been used to produce a polypropylene homopolymer or copolymer having a first molecular weight and at least part of the effluent is to be supplied to a slurry polymerization reactor to produce a polypropylene homopolymer or copolymer having a second, higher molecular weight.Type: GrantFiled: June 22, 2017Date of Patent: March 2, 2021Assignee: ExxonMobil Chemical Patents Inc.Inventors: Christopher G. Bauch, Blu E. Englehorn, Kevin W. Lawson, Todd S. Edwards, Keith W. Trapp
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Publication number: 20200140584Abstract: Disclosed is a polypropylene with an MFR of at least 20 g/10 min comprising a homopolypropylene and optionally within a range from 2 wt % to 30 wt % of an propylene-?-olefin copolymer by weight of the polypropylene; wherein the homopolypropylene has a MFR within a range from 30 g/10 min to 200 g/10 min, an Mw/Mn within a range from 7 to 16, and comprising 1.1 wt % or less atactic polypropylene based on the total weight of the homopolypropylene and atactic polypropylene, where the propylene-?-olefin copolymer has within a range from 30 wt % to 50 wt % ?-olefin derived units by weight of the propylene-?-olefin copolymer, and an intrinsic viscosity within a range from 4 to 8 dL/g. The impact copolymer may be obtained by combining a Ziegler-Natta catalyst having at least two different internal electron donors with propylene in reactors in series to produce the homopolypropylene followed by a gas phase reactor to produce a propylene-?-olefin copolymer.Type: ApplicationFiled: April 11, 2018Publication date: May 7, 2020Inventors: Christopher G. Bauch, Todd S. Edward
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Publication number: 20200131353Abstract: Disclosed is a polypropylene with an MFR of at least 20 g/10 min comprising a homopolypropylene and within a range from 2 wt % to 20 wt % of a propylene-?-olefin copolymer by weight of the polypropylene, where the homopolypropylene has a MFR within a range from 30 g/10 min to 200 g/10 min, where the propylene-?-olefin copolymer comprises within a range from 30 wt % to 50 wt % ?-olefin derived units by weight of the propylene-?-olefin copolymer, and has an IV within a range from 4 to 9 dL/g. The polypropylene may be obtained by combining a Ziegler-Natta catalyst having two transition metals with propylene in reactors in series to produce the homopolypropylene followed by a gas phase reactor to produce a propylene-?-olefin copolymer blended with the homopolypropylene.Type: ApplicationFiled: April 11, 2018Publication date: April 30, 2020Inventors: Todd S. Edwards, Christopher G. Bauch
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Patent number: 10544237Abstract: Disclosed is a method of reducing and/or regulating the level of hydrogen in a polymerization reactor comprising contacting a first feed comprising a first amount of hydrogen with a hydrogenation catalyst prior to entering a polymerization reactor to form a second feed; then contacting the second feed having a second amount of hydrogen with monomers and a polymerization catalyst in a polymerization reactor to form a polymer. The first and second feeds may reside in a feed line from one reactor to another, a monomer feed line to the reactor, or in a recycle line to and from the same reactor.Type: GrantFiled: July 25, 2016Date of Patent: January 28, 2020Assignee: ExxonMobil Chemical Patents Inc.Inventors: Christopher G. Bauch, Todd S. Edwards, Daniel L. Bilbao, Kevin W. Lawson, Blu E. Englehorn
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Patent number: 10465025Abstract: A propylene-based impact copolymer having a high gloss and suitable for appliance components comprising a polypropylene homopolymer and within a range of from 6 wt % to 20 wt % of propylene copolymer based on the weight of the impact copolymer, wherein the copolymer comprises from 20 wt % to 44 wt % ethylene, and/or C4 to C10 ?-olefin derived units and the remainder propylene-derived units based on the weight of the propylene copolymer, the impact copolymer having a melt flow rate (230° C./2.16 kg) within a range of from 10 g/10 min to 50 g/10 min.Type: GrantFiled: May 31, 2017Date of Patent: November 5, 2019Assignee: ExxonMobil Chemical Patents Inc.Inventors: Chon-Yie Lin, Todd S. Edwards, Christopher G. Bauch, Prasadarao Meka
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Publication number: 20190144573Abstract: A process for reducing the level of hydrogen in certain polymerization effluent and recycle streams containing unreacted propylene monomers and hydrogen by contacting the streams with a hydrogenation catalyst so as to convert at least part of the propylene to the corresponding alkane. The process is particularly applicable to the effluent from a slurry polymerization reactor which has been used to produce a polypropylene homopolymer or copolymer having a first molecular weight and at least part of the effluent is to be supplied to a slurry polymerization reactor to produce a polypropylene homopolymer or copolymer having a second, higher molecular weight.Type: ApplicationFiled: June 22, 2017Publication date: May 16, 2019Inventors: Christopher G. Bauch, Blu E. Englehorn, Kevin W. Lawson, Todd S. Edwards, Keith W. Trapp
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Publication number: 20180237555Abstract: Disclosed is a method of reducing and/or regulating the level of hydrogen in a polymerization reactor comprising contacting a first feed comprising a first amount of hydrogen with a hydrogenation catalyst prior to entering a polymerization reactor to form a second feed; then contacting the second feed having a second amount of hydrogen with monomers and a polymerization catalyst in a polymerization reactor to form a polymer. The first and second feeds may reside in a feed line from one reactor to another, a monomer feed line to the reactor, or in a recycle line to and from the same reactor.Type: ApplicationFiled: July 25, 2016Publication date: August 23, 2018Inventors: Christopher G. Bauch, Todd S. Edwards, Daniel L. Bilbao, Kevin W. Lawson, Blu E. Englehorn
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Publication number: 20170267794Abstract: A propylene-based impact copolymer having a high gloss and suitable for appliance components comprising a polypropylene homopolymer and within a range of from 6 wt % to 20 wt % of propylene copolymer based on the weight of the impact copolymer, wherein the copolymer comprises from 20 wt % to 44 wt % ethylene, and/or C4 to C10 ?-olefin derived units and the remainder propylene-derived units based on the weight of the propylene copolymer, the impact copolymer having a melt flow rate (230° C./2.16 kg) within a range of from 10 g/10 min to 50 g/10 min.Type: ApplicationFiled: May 31, 2017Publication date: September 21, 2017Inventors: Chon-Yie Lin, Todd S. Edwards, Christopher G. Bauch, Prasadarao Meka
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Patent number: 9745395Abstract: A propylene-based impact copolymer (ICP) and composition including the ICP, the ICP comprising a polypropylene homopolymer and within the range of from 10 wt % to 45 wt % of propylene copolymer based on the weight of the ICP, wherein the copolymer comprises from 20 wt % to 44 wt % ethylene, 1-butene, 1-hexene and/or 1-octene derived units and from 80 to 60 wt % propylene-derived units based on the weight of the propylene copolymer, the propylene-based impact copolymer having a Melt Flow Rate (230° C./2.16 kg) within the range of from 10 g/10 mm to 50 g/10 mm and an Elongation at Break of greater than 70%.Type: GrantFiled: March 4, 2016Date of Patent: August 29, 2017Assignee: ExxonMobil Chemical Patents Inc.Inventors: Prasadarao Meka, Chon-Yie Lin, Todd S. Edwards, Christopher G. Bauch
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Patent number: 9605096Abstract: A method is provided for polymerizing an olefin monomer in a reactor with a highly active polyolefin polymerization catalyst system. The method includes introducing a catalyst system comprising a catalyst and a catalyst activator into the reactor containing the olefin monomer with less than 10 seconds or no pre-contacting time of the catalyst and the catalyst activator prior to introducing the catalyst and the catalyst activator into the reactor. The catalyst system may have a standard adjusted catalyst activity of greater than 10 gPgcat?1hr?1.Type: GrantFiled: June 5, 2014Date of Patent: March 28, 2017Assignee: ExxonMobil Chemical Patents Inc.Inventors: Todd S. Edwards, Kevin W. Lawson
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Publication number: 20170022308Abstract: A propylene-based impact copolymer (ICP) and composition including the ICP, the ICP comprising a polypropylene homopolymer and within the range of from 10 wt % to 45 wt % of propylene copolymer based on the weight of the ICP, wherein the copolymer comprises from 20 wt % to 44 wt % ethylene, 1-butene, 1-hexene and/or 1-octene derived units and from 80 to 60 wt % propylene-derived units based on the weight of the propylene copolymer, the propylene-based impact copolymer having a Melt Flow Rate (230° C./2.16 kg) within the range of from 10 g/10 mm to 50 g/10 mm and an Elongation at Break of greater than 70%.Type: ApplicationFiled: March 4, 2016Publication date: January 26, 2017Inventors: Prasadarao Meka, Chon-Yie Lin, Todd S. Edwards, Christopher G. Bauch
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Patent number: 9453093Abstract: Polypropylene resin comprising at least 50 mol % propylene, an MWD (Mw/Mn) of greater than 5, a branching index (g?) of at least 0.95, and a melt strength of at least 20 cN determined using an extensional rheometer at 190° C. A catalyst system comprising a Ziegler-Natta catalyst comprising a non-aromatic internal electron donor, and first and second external electron donors comprising different organosilicon compounds, and a method to produce a polypropylene resin comprising contacting propylene monomers at propylene polymerization conditions with the catalyst system are also disclosed.Type: GrantFiled: October 8, 2013Date of Patent: September 27, 2016Assignee: ExxonMobil Chemical Patents Inc.Inventors: Prasadarao Meka, Saifudin M. Abubakar, Yumin Chen, Todd S. Edwards
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Patent number: 9309334Abstract: A propylene-based impact copolymer (ICP) and composition including the ICP, the ICP comprising a polypropylene homopolymer and within the range of from 10 wt % to 45 wt % of propylene copolymer based on the weight of the ICP, wherein the copolymer comprises from 20 wt % to 44 wt % ethylene, 1-butene, 1-hexene and/or 1-octene derived units and from 80 to 56 wt % propylene-derived units based on the weight of the propylene copolymer, the propylene-based impact copolymer having a Melt Flow Rate (230° C./2.16 kg) within the range of from 10 g/10 min to 50 g/10 min and an Elongation at Break of greater than 70%.Type: GrantFiled: December 11, 2014Date of Patent: April 12, 2016Assignee: ExxonMobil Chemical Patents Inc.Inventors: Prasadarao Meka, Chon-Yie Lin, Todd S. Edwards, Christopher G. Bauch
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Publication number: 20150252127Abstract: Polypropylene resin comprising at least 50 mol % propylene, an MWD (Mw/Mn) of greater than 5, a branching index (g?) of at least 0.95, and a melt strength of at least 20 cN determined using an extensional rheometer at 190° C. A catalyst system comprising a Ziegler-Natta catalyst comprising a non-aromatic internal electron donor, and first and second external electron donors comprising different organosilicon compounds, and a method to produce a polypropylene resin comprising contacting propylene monomers at propylene polymerization conditions with the catalyst system are also disclosed.Type: ApplicationFiled: October 8, 2013Publication date: September 10, 2015Inventors: Prasadarao Meka, Saifudin M. Abubakar, Yumin Chen, Todd S. Edwards