Narrow MWD alpha-olefin copolymers

Claim 2

In a polymerization process for producing copolymer in the form of copolymer chains, from a reaction mixture comprised of catalyst, ethylene, and at least one other alpha-olefin monomer, the improvement which comprises conducting the polymerization: (a) in at least one mix-free reactor, (b) with essentially one active catalyst species, (c) using at least one reaction mixture which is essentially transfer agent-free, and (d) in such a manner and under conditions sufficient to initiate propagation of essentially all of said copolymer chains simultaneously, wherein the copolymer chains are dispersed within the reaction mixture.

Claim 3

A process according to claim 1, wherein the catalyst comprises hydrocarbon-soluble vanadium compound and organo-aluminum compound which react to form essentially one active catalyst species, at least one of the vanadium compound and organo-aluminum compound containing a valence-bonded halogen.

Claim 4

A process according to claim 1 or 2, wherein the inlet temperature of the reaction mixture is about -50° C. to 150° C.

Claim 5

A process according to claim 3, wherein the maximum outlet temperature of the reaction mixture is about 200° C.

Claim 6

A process according to claim 3, wherein the catalyst components are premixed, and wherein the polymerization is a solution polymerization.

Claim 7

A process according to claim 5, wherein the catalyst components are aged for at least about 0.5 seconds.

Claim 8

A process according to claim 2, wherein the mole ratio of aluminum to vanadium in the catalyst is about 2 to 25.

Claim 9

A process according to claim 5, wherein the reaction mixture leaving the reactor has a copolymer concentration of about 3 to 15% on a weight of copolymer per weight of solvent basis.

Claim 10

A process according to claim 1, wherein the catalyst comprises a Ziegler catalyst.

Claim 11

a process according to claim 3, wherein the maximum outlet temperature of the reaction mixture is about 50° C.

Claim 12

A process according to claim 8, wherein the catalyst comprises components that are premixed and then aged for about 1 to 50 seconds.

Claim 13

A process according to claim 8, wherein the mole ratio of aluminum to vanadium in the catalyst is about 4 to 15.

Claim 14

A process according to claim 12, wherein the polymerization is conducted in a solvent for the reaction mixture, and wherein the reaction mixture leaving the reactor has a copolymer concentration of about 3% to 10% on a weight of polymer per weight of solvent basis.

Claim 15

A process according to claim 2, wherein the catalyst comprises: (a) hydrocarbon-soluble vanadium compound selected from the group consisting of: ##STR3## where x=0-3 and R=hydrocarbon radical; VCl 4 ; VO(AcAc) 2 , where AcAc=acetyl acetonate V(AcAc) 3 , where AcAc=acetyl acetonate VOCl x (AcAc) 3-x , where x=1 or 2 and AcAc=acetyl acetonate; and VCl 3 .nB, where n=2-3 and B=Lewis base capable of forming hydrocarbon-soluble complexes with VCl 3 ; and (b) organo-aluminum compound selected from the group consisting of: AlR 3 AlR 2 Cl, Al 2 R 3 Cl 3 , AlRCl 2 , AlR'RCl, Al(OR')R 2 , R 2 Al-OAlR 2 , and AlR 2 I, where R and R' are hydrocarbon radicals.

Claim 16

A process according to claim 2, wherein the catalyst comprises VCl 4 and Al 2 R 3 Cl 3 .

Claim 17

A process according to claim 4, wherein the maximum outlet temperature of the reaction mixture is about 70° C.

Claim 18

A process according to claim 16, wherein the polymerization is adiabatic.

Claim 19

A process according to claim 17, wherein the catalyst comprises one active species which provides for at least 65% of the total copolymer produced.

Claim 20

A process according to claim 18, which is continuous and is conducted in hexane solvent.

Claim 21

A process according to claim 1, wherein said copolymer product is cured.

Claim 22

A process according to claim 1, wherein said polymerization is conducted in at least one tubular reactor.

Claim 23

A process according to claim 21, wherein said reaction mixture further comprises diene, and wherein at least one of said ethylene, other alpha-olefin monomer and diene are fed to said tubular reactor at multiple feed sites.

Claim 24

A process according to claim 1 or 14, wherein the copolymer produced has a total ethylene content of greater than about 25% on a weight basis.

Claim 25

A process according to claim 1 or 14, wherein the catalyst components are premixed.