A method of polymerizing a first, and a second class of monomers to form product polymer. The first class of monomers polymerize via a radical pathway in the presence of light, and the second class of monomers polymerize via an insertion pathway in the absence of light.

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. Such thus-produced TPVs have a lower hysteresis and flexural modulus, and better elastic properties.

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. Such thus-produced TPVs have a lower hysteresis and flexural modulus, and better elastic properties.

The present application provides a catalyst component for alkene polymerization. The catalyst component contains: (a) a group 4 transition metal or rare earth metal, (b) a rigid non-cyclopentadienyl ligand with a tricyclic backbone composed of three ortho-fused 6-membered rings in a linear arrangement (as is the case in xanthene), with or without additional fused rings; the tricyclic backbone contains at least one donor atom within the central ring (as is the case for xanthene, oxanthrene, or acridan); furthermore, donor atoms/groups or aryl rings are attached directly (i.e. via the donor atom in the case of donor groups) to both of the bondable carbon atoms adjacent to at least one of the donor atoms within the central ring (e.g. xanthene with two donor groups, or two aryl rings, or one donor group and one aryl ring adjacent to oxygen), and (c) two or more activatable ligands, such as chloro, alkyl, aryl, allyl or hydride ligands, attached to the central metal if the complex is neutral or anionic, or one or more activatable ligand if the complex is monocationic or dicationic. The rigid non-cyclopentadienyl ligand has a charge of 0, 1- or 2- (considering all donor atoms of the ligand to have an octet of valence electrons). The catalyst component is optionally combined with an activator, typically for the purpose of generating a highly active monocationic or dicationic polymerization catalyst, and the catalyst and/or catalyst components may be in solution, precipitated from solution, or optionally carried on a support.

The present application provides a catalyst component for alkene polymerization. The catalyst component contains: (a) a group 4 transition metal or rare earth metal, (b) a rigid non-cyclopentadienyl ligand with a tricyclic backbone composed of three ortho-fused 6-membered rings in a linear arrangement (as is the case in xanthene), with or without additional fused rings; the tricyclic backbone contains at least one donor atom within the central ring (as is the case for xanthene, oxanthrene, or acridan); furthermore, donor atoms/groups or aryl rings are attached directly (i.e. via the donor atom in the case of donor groups) to both of the bondable carbon atoms adjacent to at least one of the donor atoms within the central ring (e.g. xanthene with two donor groups, or two aryl rings, or one donor group and one aryl ring adjacent to oxygen), and (c) two or more activatable ligands, such as chloro, alkyl, aryl, allyl or hydride ligands, attached to the central metal if the complex is neutral or anionic, or one or more activatable ligand if the complex is monocationic or dicationic. The rigid non-cyclopentadienyl ligand has a charge of 0, 1- or 2- (considering all donor atoms of the ligand to have an octet of valence electrons). The catalyst component is optionally combined with an activator, typically for the purpose of generating a highly active monocationic or dicationic polymerization catalyst, and the catalyst and/or catalyst components may be in solution, precipitated from solution, or optionally carried on a support.

In some embodiments, the present disclosure provides for ethylene-C.sub.3 to C.sub.20 alpha-olefins random copolymers having an ethylene content of about 45 wt % to about 70 wt % and a Mw(DRI)/Mn(DRI) of from 1.1 to 1.9. In some embodiments, the ethyl-C ene-propylene random copolymer is used as a viscosity modifier in a lubricating composition.

In some embodiments, the present disclosure provides for ethylene-C.sub.3 to C.sub.20 alpha-olefins random copolymers having an ethylene content of about 45 wt % to about 70 wt % and a Mw(DRI)/Mn(DRI) of from 1.1 to 1.9. In some embodiments, the ethyl-C ene-propylene random copolymer is used as a viscosity modifier in a lubricating composition.

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

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

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