Abstract: A gas-phase olefin polymerization process in a plug flow reactor uses a catalyst system containing a magnesium halide supported titanium-containing component, an organoaluminum component, and at least one external electron donor component; in the process a first external donor component is added to the reactor at an injection point axially near an injection point for the supported transition metal containing component, and at least a second external donor component is added to the reactor axially downstream from the injection point for the first external donor component.

Abstract: Block copolymers comprise at least two hard blocks S1 and S2 made from vinylaromatic monomers and, between these, at least one random soft block B/S made from vinylaromatic monomers and from dienes, where the proportion of the hard blocks is above 40% by weight, based on the total block copolymer.

Abstract: A process for transitioning between two catalysts is disclosed, comprising the steps of a) discontinuing the feed of the first catalyst into the polymerization reactor, and then b) introducing the second catalyst into the reactor, wherein one of the catalysts comprises a late transition metal catalyst and the other is a catalyst which is incompatible therewith. It is preferred that the late transition metal catalyst is a 2,6-diacetyl pyridine iron catalyst.

Abstract: The present invention provides to overcome the deficiencies of the prior art, the present invention provides a method of producing a polymer. The method includes taking a product stream from a monovinyl aromatic polymerization system wherein the product stream comprises a polymerized monomer and a monomer. The product stream is introduced into an up-flow heat exchanger in a presence of an initiator, such as a peroxide, that affects a polymerization of the monomer in the up-flow heat exchanger. The initiator may include a low-temperature initiator and a high-temperature initiator where a ratio of the high-temperature initiator to the low-temperature initiator can range from about 0:600 to about 50:600.

Abstract: This invention is related to a polymerization method wherein an atom transfer radical polymerization of a vinyl monomer is carried out under at least one condition selected from the group consisting of the following (1), (2), (3) and (4): (1) in a substantially anhydrous system; (2) in the presence of a nitrile compound; (3) addition, to the system, of a ligand to the polymerization catalyst to thereby initiate the polymerization; (4) varying a polymerization catalyst activity during polymerization to thereby control the rate of polymerization.

Abstract: A process for preparing vinyl aromatic-allylic alcohol copolymers, such as styrene-allyl alcohol (SAA) copolymers, is disclosed. The process is conducted in the presence of a solvent, which enables the preparation of copolymers having both low hydroxyl functionalities and low molecular weights. SAA copolymers produced by the process have an average hydroxyl functionality less than about 4.

Abstract: The invention relates to a polyphenylene ether resin containing residual aliphatic unsaturation as well as composites, blends, and articles made from the polyphenylene ether resin containing residual aliphatic unsaturation. Also included are reaction products between the polyphenylene ether resin containing residual aliphatic unsaturation and other resins and unsaturated resin formulations, e.g., thermosetting polyesters, acrylics, bismaleiimides, silicones, and allylics, and thermoplastics such as polyolefins, styrenics, rubbers, etc.

Abstract: Crystalline polypropylene contains components insoluble in 64° C. decane satisfying the characteristics involving intrinsic viscosity; Mz/Mn; pentadvisotacticity, D value and Mw/Mn, are excellent in hardness and rigidity, high in melt tension, and excellent in molding properties. Processes for preparing such crystalline polypropylenes, and polypropylene compositions and thermoformed products that contain such crystalline polypropylenes are also described. The number-average molecular weight Mn of the components insoluble in 64° C. decane is preferably 25000 or more.

Abstract: A process for introducing a solid catalyst particle feed into a fluidised or agitated vessel utilising a feed delivery device, a vertical feed dilution pipe and a feed injection pipe connected to the vessel, the process including the steps of: (a) introducing the solid catalyst particles feed from the feed delivery device into the vertical feed dilution pipe, (b) diluting the solid catalyst particles feed by letting the solid particle reaching by gravity their terminal velocity in the feed dilution pipe, (c) introducing the diluted solid catalyst particles feed into the injection pipe and mixing it with conveying gas, and introducing the gas conveyed diluted solid catalyst particles feed into the vessel.

Abstract: A process, carried out in the gas phase, comprising contacting one or more olefins with a catalyst system containing a carrier gas and a mixture of solids comprising a transition metal compound or complex and a liquid organic solvent, under polymerization conditions, in a fluidized bed reactor containing resin particles in a fluidized state with the provisos that (a) the mixture of solids and solvent contains at least about 95 percent by weight solids and (b) the mixture is sprayed with the carrier gas into a particle-lean zone, or the fluidized bed, of the reactor.

Abstract: The present invention provides a novel, optionally surfactant-free process for controlling particle number, particle size, and/or particle size distribution. The method of the invention also significantly improves monomer to polymer conversion rates, as well as, increases the level of polymer solids which can be emulsified/dispersed in water without polymer flocculation. Specifically, the improved process provides an aqueous dispersion of up to about 48% polymer solids in water in the absence of surfactant. The resulting fluoropolymers dispersions may be used in resin and coating applications.

Abstract: A novel loop/slurry olefin polymerization process is provided which produces ultra high molecular weight ethylene homopolymers and ultra high molecular weight ethylene copolymers. Catalyst systems used are selected from the group consisting of inorganic oxide supported titanium-containing catalyst systems, inorganic oxide supported organo-zirconium catalyst systems and inorganic oxide supported organo-hafnium catalyst systems.

Abstract: A device and method allow a dry catalyst to be delivered to a liquid-filled polymerization reactor, thus avoiding problems associated with catalyst-liquid contact or with undesired addition of gases to the reactor. A quantity of dry catalyst is transferred from a catalyst reservoir maintained under dry conditions to a catalyst chamber. An inert fluid then enters the chamber to flush the catalyst charge toward the reactor. Optional embodiments include means for precontacting the dry catalyst with a modifier and for removing gas from the fluid line.

Abstract: A device and method allow a dry catalyst to be delivered to a liquid-filled polymerization reactor, thus avoiding problems associated with catalyst-liquid contact or with undesired addition of gases to the reactor. A quantity of dry catalyst is transferred from a catalyst reservoir maintained under dry conditions to a catalyst chamber. An inert fluid then enters the chamber to flush the catalyst charge toward the reactor. Optional embodiments include means for precontacting the dry catalyst with a modifier and for removing gas from the fluid line.

Abstract: The present invention presents crystalline polypropylenes that contain components insoluble in 64° C. decane that satisfy the following characteristics (1) to (4) and are excellent in hardness and rigidity, high in melt tension, and excellent in molding properties, process for preparing such crystalline polypropylenes, and polypropylene compositions and thermoformed products that contain such crystalline polypropylenes.

Abstract: Process for the preparation of polyvinylarene polymer particles by suspension polymerization, wherein (a) vinylarene monomers are suspended in an aqueous medium to yield a suspension; (b) the temperature of the suspension is adjusted to a temperature above 50° C., at which temperature an initiator is added; (c) subsequently, the reaction temperature is increased by 5 to 30° C. per hour until a temperature of at least 120° C. has been reached; and (d) the temperature is retained at a temperature of at least 120° C. until the polymerization is complete.

Abstract: This invention relates to a process to polymerize olefins comprising reacting olefins with a combined catalyst system comprising a hydrogen generating olefin polymerization catalyst and from 10 ppm to 10 weight % of at least one hydrogen consuming olefin polymerization catalyst system, based upon the weight of the total catalyst present, not including any activators or supports.

Abstract: The present invention provides a novel, optionally surfactant-free process for controlling particle number, particle size, and/or particle size distribution. The method of the invention also significantly improves monomer to polymer conversion rates, as well as, increases the level of polymer solids which can be emulsified/dispersed in water without polymer flocculation. Specifically, the improved process provides an aqueous dispersion of up to about 48% polymer solids in water in the absence of surfactant. The resulting fluoropolymers dispersions may be used in resin and coating applications.

Abstract: An olefin (co)polymer composition comprising, as major components, (a) 0.01 to 5 parts by weight of an olefin (co)polymer having an intrinsic viscosity [.eta..sub.a ] as measured in 135.degree. C. tetralin of 15 to 100 dl/g and (b) 100 parts by weight of an olefin (co)polymer obtained by using a metallocene catalyst and having an intrinsic viscosity [.eta..sub.b ] as measured in 135.degree. C. tetralin of 0.2 to 10 dl/g. When polyethylene having a high degree of polymerization is produced before a so-called metallocene catalyst is used to polymerize, e.g., propylene in the presence of the polyethylene as a component of a catalyst composition, a polypropylene composition having a high melt tension and a high crystallization temperature is produced.

Abstract: The use of perpendicular spray nozzles to deliver liquid catalyst to a gas-phase polymerization reactor is taught. Moreover, a method of reducing the amount of gas needed to deliver catalyst is also taught.

Abstract: A process for the radical polymerization of ethylenically unsaturated monomers in an aqueous medium has (a) the starting solution used for the polymerization and the educts required for polymerization such as monomers, germ latex, buffering agents, emulsifiers and/or protective colloids are introduced into a pre-mixing device and thoroughly mixed, heated before being transferred to the polymerization vessel to the polymerization temperature, no initiator being used if a thermal radical initiator is used and only individual initiator components being used where a redox initiator system is used; (b) once the mixture has reached polymerization temperature, it is transferred to a polymerization vessel, the wall of which during the transfer and polymerization is maintained by cooling at a temperature below the polymerization temperature; polymerization is started by adding the thermal initiator or additional initiator components of the redox initiator system, the other educts being added at the start of and/or dur

Abstract: A method of controlling the molecular weight distribution of a polyalpha-olefin during polymerization, comprising changing the aluminoxane to chromium ratio of a polymerization catalyst comprising chromium and at least one aluminoxane to thereby adjust the molecular weight distribution.

Abstract: A process for controlling the molecular weight distribution of polyisobutene formed during a liquid phase polymersiation reaction using a catalyst comprising boron trifluoride and taking place in a reactor having condensers associated with it which process involves introducing an electron donor above the level of liquid in the reactor to minimize the reaction of isobutene with free gaseous boron trifluoride in the condensers thereby minimizing the formation of unwanted polymers.

Abstract: The present invention teaches the use of an effervescent nozzle to deliver liquid catalyst to a gas phase polymerization system.

Abstract: The present invention is a free radical bulk polymerization process for the preparation of high molecular weight polymers from vinyl aromatic monomers, characterized in that the polymerization is conducted in the presence of a vinyl acid containing either a sulfur or phosphorus atom within the acid functional group.

Abstract: The present invention provides a novel, optionally surfactant-free process for controlling particle number, particle size, and/or particle size distribution. The method of the invention also significantly improves monomer to polymer conversion rates, as well as, increases the level of polymer solids which can be emulsified/dispersed in water without polymer flocculation. Specifically, the improved process provides an aqueous dispersion of up to about 48% polymer solids in water in the absence of surfactant. The resulting fluoropolymers dispersions may be used in resin and coating applications.

Abstract: For gas phase polymerization reactions in the presence of an unsupported polymerization catalyst, there is provided a process for introducing a liquid catalyst so as to provide a resin particle lean zone such that the average particle size of the resin produced ranges from about 0.01 to about 0.06 inches.

Abstract: The present invention is an improvement in a free radical bulk polymerization process for preparing a high molecular weight polymer from a vinyl aromatic monomer characterized in that the polymerization is conducted in the presence of an acid catalyst having a pKa at 25.degree. C. of less than 2, or salt thereof, wherein the improvement comprises dispersing the acid catalyst, or salt thereof, in a (meth)acrylic acid or ester thereof, prior to contact with the vinyl aromatic monomer. The (meth)acrylic acid or ester allows the acid catalyst to be dispersed within the vinyl aromatic monomer without causing cationic polymerization. The acid catalyst, or salt thereof, catalyzes the free radical polymerization reaction such that high molecular weight polymers are produced in reasonable reaction times.

Abstract: An improved process for making vinyl aromatic/allylic alcohol copolymers is disclosed. Gradual addition of a free-radical initiator during the course of the polymerization results in a substantial increase in the polymer yield obtained compared with the yield from conventional processes in which all of the free-radical initiator is charged initially. High yields are obtained when the monomer mole ratios are adjusted to produce styrene-allyl alcohol copolymers having a hydroxyl number in the 50-150 mg KOH/g range. Copolymers made by the process are valuable coating resins.

Abstract: A process of preparing an elastomeric copolymer composition of mono-vinyl aromatic hydrocarbon and conjugated diene is disclosed. The composition produced by this process has preferred properties, i.e. the product possesses the characteristics of enhancing ultimate elongation up to 900%, keeping tensile strength in a suitable range and enhancing transparency.

Abstract: A process for preparing perfluoroelastomer compositions which comprise perfluoroelastomers having a plurality of nitrile groups and a plurality of carboxyl-containing groups, carboxylate-containing groups, carboxamide groups, or mixtures thereof is provided. Such compositions cure rapidly in the presence of organotin compounds.

Abstract: Disclosed is a process for the preparation of a polymer which comprises effecting bulk polymerization of a mixture of at least one monomer, a free radical polymerization initiator, and a stable free radical agent until from about 10 to about 50 weight percent of the monomer has been polymerized; optionally adding additional free radical initiator; optionally adding a colorant; dispersing with a high shear mixer the aforementioned partially polymerized mixture in water containing a stabilizing component selected from the group consisting of non-ionic and ionic water soluble polymeric stabilizers to obtain a suspension of particles with an average diameter of from about 0.1 to about 10 microns; polymerizing the resulting suspension to form said polymer.

Abstract: The synthesis and characterization of novel linear polymers and multi-arm star polymers comprising polyisobutylene arms connected to a well-defined calixarene core are described. The polymers are directly telechelic. They synthesis has been achieved using the "core first" method wherein multifunctional calix?n!arene (where n=4 to 16) derivatives or their monofunctional analogues are used as initiators which, in conjunction with certain Freidel-Crafts acids as co-initiators, induce the living polymerization of isobutylene or a similar carbocationic polymerizable monomer. Novel initiators suitable for inducing the polymerization are also described.

Abstract: Process with two or more steps for the preparation in suspension of mixtures of ethylene-propylene (EPM) elastomer homopolymers or ethylene-propylene-diene (EPDM) elastomer terpolymers in the presence of a catalytic system essentially consisting of a compound of Vanadium and a cocatalyst essentially consisting of an Aluminum alkyl and in the presence of an activator, the above process being characterized in that:a) in the first step a first polymerization of the monomers is carried out in the presence of the Vanadium based catalyst;b) in the second or subsequent steps further polymerizable monomers and activator are added to the suspension of the polymer obtained in step (a).

Abstract: This invention relates to a process for transitioning between incompatible polymerization catalyst systems. Particularly, the invention relates to a process for transitioning from an olefin polymerization reaction utilizing a traditional Ziegler-Natta catalyst system to a metallocene-olefin polymerization reaction.

Abstract: A free radical polymerization process for the preparation of a polymer comprising heating a mixture of a free radical initiator, a stable free radical agent, a metal catalyst, or a metal stable free radical complex catalyst, and at least one polymerizable monomer; cooling said mixture; and optionally isolating said polymer.

Abstract: This invention relates to block polymers containing both crystalline and elastomeric blocks, the block copolymer having an A block and a B block. The A block is a polyethylene or an ethylene polymer optionally containing an alpha-olefin and is generally crystalline. The B block contains an ethylene, .alpha.-olefin copolymer segment and optionally contain an ethylene, .alpha.-olefin, non-conjugated diene terpolymer segment. If the B block contains a diene containing segment, the diene containing segment is furthest from the junction of the A and the B blocks. Also disclosed is a process for manufacture of the block copolymers and methods for coupling the block copolymers. Coupled block copolymers are useful as thermoplastic elastomers exhibiting physical properties approaching those of crosslinked EP or EPDM elastomers, but showing thermal processability after coupling.

Abstract: For gas phase polymerization reactions in the presence of an unsupported polymerization catalyst, there is provided a process for introducing a liquid catalyst so as to provide a resin particle lean zone such that the average particle size of the resin produced ranges from about 0.01 to about 0.06 inches.

Abstract: A process for the preparation of a synthetic resin dispersion stabilized by a protective colloid employing at least one initiator and based on a polymer of (a) a first monomer of at least one ester of acrylic acid or methacrylic acid and an alcohol containing 1 to 22 carbon atoms; and optionally, (b) a second monomer which can be copolymerized with the first monomers. The process comprises introducing at least 50% of the monomers based on the total weight of the monomers, at least 50% of the protective colloid based on the total weight of the protective colloid, and up to 50% of the initiator based on the total weight of the initiator into a reaction vessel to form an aqueous emulsion. Any remaining monomers and protective colloid and at least 50% of the initiator based on the total weight of the initiator are then added to the reaction vessel at a temperature of 30.degree. to 100.degree. C.

Abstract: This invention relates to a process for transitioning between incompatible polymerization catalyst systems. Particularly, the invention relates to a process for transitioning from an olefin polymerization reaction utilizing a traditional Ziegler-Natta catalyst system to a metallocene-olefin polymerization reaction.

Abstract: The invention provides a continuous process for catalytically polymerizing a monomer feed of ethylene and at least one comonomer which comprises introducing a catalyst including a bulky ancillary ligand transition metal compound and monomer feed in an upstream reaction zone for polymerization, introducing further catalyst in a downstream reaction zone for further polymerization, the peak temperature in the downstream reaction zone being at least 50.degree. C. higher than in the upstream zone and being above 150.degree. C. The process economically produces polymer of good properties which is melt processable.

Abstract: A method for the production of a microsphere without use of a dispersion stabilizer is disclosed which permits the microsphere to be produced in the form of discrete particles readily treatable for purification. The method which produces this microsphere comprises the steps of dissolving in an organic solvent such as an alcohol a monomer mixture including an ethylenically unsaturated amide and 10 to 70% by weight, based on 100% by weight of said monomer mixture, of a cross-linking agent thereby preparing a mixed solution, keeping said mixed solution at a temperature in the range of from 30.degree. to 95.degree. C., and adding thereto at least one initiator selected from the group consisting of peroxide type initiators and azo type initiators in an amount such as to be contained therein at a final concentration in the range of from 1.times.10.sup.-5 to 8.times.10.sup.-2 mol/liter thereby inducing polymerization of said monomer mixture.

Abstract: An improved process for preparing core/shell MBS modifiers is disclosed, wherein by adding feeds of the monomers which form the second and/or third stage polymers prior to completion of polymerization of the earlier stages, a process with substantially reduced polymerization time results with no loss in properties of the product. The process further includes agglomeration of the rubbery polymer to increase particle size during the polymerization process.

Abstract: There is disclosed a process for continuously producing a highly syndiotactic styrenic polymer by using a horizontal self-cleaning type reactor which comprises feeding into the reactor, a catalyst or both the catalyst and a styrenic monomer dividedly into at least two portions, preferably 2 to 5 portions in the direction of the axis of the reactor. The above process facilitates the control for the reactor inside temperatures because of the stepwise feeding of the catalyst (and the styrenic monomer) and remarkably enhances the productivity by simply increasing the feed rates of the catalyst and the styrenic monomer, thus making itself industrially highly valuable.

Abstract: In one of several methods of producing polybutadiene or a butadiene-styrene copolymer with an organolithium initiator, an organotin compound such as tetraallyltin, tetrabenzyltin and tetraphenyltin is added to the polymerization system in a period of growth of the polymer chain between a time immediately after a start of the polymerization to a time before an end of the polymerization. In another of the methods, tin tetrachloride or tin dichloride is added at an earlier time after a start of the polymerization. A polymer comprising a considerable amount of high molecular weight polymer containing the chain having a tin-carbon linkage is formed. A rubber composition for tires comprises specified amounts of the polymer described above, natural rubber, carbon black and vulcanizing agents. The rubber composition has a small loss factor and excellent fracture properties.

Abstract: The invention comprise a composition for breaking oil-in-water emulsions comprising adding from about 1 part per million to about 500 parts per million of an amphoteric acrylic acid copolymer to the emulsion. Once the copolymer is added, the emulsion is subjected to agitation until the oil-in-water emulsion is resolved and the oil and water separates into two phases. The oil and water phases are then subjected to a separation technique to separate the phases. The invention further comprises a method of synthesizing the amphoteric polymers used in the emulsion breaking application.

Abstract: An improved process for preparing core/shell MBS modifiers is disclosed, wherein by adding feeds of the monomers which form the second and/or third stage polymers prior to completion of polymerization of the earlier stages, a process with substantially reduced polymerization time results with no loss in properties of the product. The process further includes agglomeration of the rubbery polymer to increase particle size during the polymerization process.

Abstract: A process for producing polypropylene is provided which comprises polymerizing propylene in multiple stages, in the presence of a catalyst which is prepared by reacting a first organoaluminum compound (i), or a reaction product (vi) formed between the first organoaluminum compound (i) and an electron donor (a), with titanium tetrachloride (c) to obtain a first solid product (ii), reacting the resulting first solid product (ii) with the electron donor (a) and an electron acceptor (b) to obtain a second solid product (iii), and combining the resulting second solid product (iii) with a second organoaluminum compound (iv) and an aromatic carboxylic acid ester (v) at a molar ratio of the aromatic carboxylic acid ester to the second solid product (v/iii molar ratio) of from 0.1 to 10.

Abstract: A bimetallic catalyst produces broad or bimodal molecular weight distribution polyolefin resin whose composition depends on the ratio of the concentration of the two metals of the catalyst producing the HMW and LMW components. The bimetallic catalyst produces a broad/bimodal MWD resin whose HMW and LMW components depend on the relative productivity of each of the transition metal sites of the catalyst. Water and/or carbon dioxide are cofed to the polymerization reactor at levels necessary to modify the weight fractions of the HMW and LMW components, thus achieving a target molecular weight distribution, MWD. The invention allows the resin MWD to be adjusted in the reactor. The weight fraction of the high molecular weight component decreases with the addition of the water and or the carbon dioxide and the FI of the overall product increases with a decrease in the HMW component weight fraction in the product.

Abstract: An improved process for making vinyl aromatic/allylic alcohol copolymers is disclosed. Gradual addition of a free-radical initiator during the course of the polymerization results in a substantial increase in the polymer yield obtained compared with the yield from conventional processes in which all of the free-radical initiator is charged initially. The process is particularly useful for making commercially important varieties of styrene-allyl alcohol copolymers.