Olefin polymerization process

Abstract

A copolymer of ethylene and a higher alpha-olefin having broadened melt processing windows and reduced melt fracture can be produced using a chromium-containing catalyst system and a trialkyl boron cocatalyst. The polymerization process must be carefully controlled to produce a copolymer resin that easily can be made into articles of manufacture.

That which is claimed:  
     
         1 . A polymerization process comprising contacting in a reaction zone, at a temperature within a range of about 180° F. to about 215° F., in the absence of hydrogen: 
 a) ethylene monomer;  
 b) at least one mono-1-olefin comonomer having from about 2 to about 8 carbon atoms per molecule;  
 c) a catalyst system comprising chromium supported on a silica-titania support, wherein said support comprises from about 2 to about 10 weight percent titanium, based on the weight of the support, and wherein said catalyst system has been activated at a temperature within a range of about 900° F. to about 1050° F.; and  
 d) a trialkyl boron compound;  
 and recovering an ethylene/mono-1-olefin copolymer.  
 
     
     
         2 . A process according to  claim 1  wherein said reaction zone temperature is within a range of about 180° F. to about 195° F.  
     
     
         3 . A process according to  claim 1  wherein said mono-1-olefin comonomer is selected from the group consisting of propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 4-methyl-1-pentene, and mixtures thereof.  
     
     
         4 . A process according to  claim 1  wherein said catalyst system is activated at a temperature within a range of about 965° F. to about 1020° F.  
     
     
         5 . A process according to  claim 1  wherein said trialkyl boron compound is selected from the group consisting of tri-n-butyl borane, tripropylborane, triethylborane, and mixtures thereof.  
     
     
         6 . A process according to  claim 3  wherein said comonomer is 1-hexene.  
     
     
         7 . A process according to  claim 5  wherein said trialkyl borane compound is triethylborane.  
     
     
         8 . A process according to  claim 1  wherein said ethylene copolymer comprises: 
 a) a density within a range of about 0.935 g/cc to about 0.96 g/cc;  
 b) a high load melt index within a range of about 0.5 g/10 minutes to about 30 g/10 minutes; and  
 c) a critical shear rate for the onset of melt fracture of greater than or equal to about 1200 sec −1 .  
 
     
     
         9 . A composition comprising an ethylene/higher mono-1-olefin copolymer having: 
 a) a density within a range of about 0.935 g/cc to about 0.96 g/cc;    b) a high load melt index within a range of about 0.5 g/10 minutes to about 30 g/10 minutes; and    c) a critical shear rate for the onset of melt fracture of greater than about 1200 sec −1 .    
     
     
         10 . A copolymer according to  claim 9  having a density within a range of about 0.940 g/cc to about 0.955 g/cc.  
     
     
         11 . A copolymer according to  claim 9  having a high load melt index within a range of about 1 g/10 minutes to about 20 g/10 minutes.  
     
     
         12 . A copolymer according to  claim 9  having a critical shear rate for the onset of melt fracture of greater than about 1900 sec −1 .