Catalysts for polymerization or copolymerization of α-olefins, catalyst components thereof, and processes for polymerization of α-olefins with the catalysts

• US 7,238,758 B2
• Filed: 08/19/2003
• Issued: 07/03/2007
• Est. Priority Date: 08/19/2002
• Status: Active Grant

• Current Assignee: TOHO Titanium Company Limited (ENEOS Holdings, Inc.)
• Original Assignee: UBE Industries Limited
• Inventors: Machida, Toshikazu, Sato, Hiroshi, Tanaka, Yasuhiro, Ikeuchi, Hiroyuki, Yano, Takefumi, Fukunaga, Toshifumi, Yoshikiyo, Motozo
• Primary Examiner(s): Choi; Ling-Sui
• Application Number:
  US10/503,414
• Publication Number:
  US 20050202958A1
• Time in Patent Office: 1,414 Days
• Field of Search: 526/351, 526/348, 526/904, 526/141, 526/125.6, 526/125.3, 526/126, 526/128, 502/123, 502/103, 502/115, 502/116
• US Class Current: 526/128
• CPC Class Codes: C07F 7/025 without C-silicon linkages
• CPC Class Codes: C08F 10/00 Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
• CPC Class Codes: C08F 10/06 Propene
• CPC Class Codes: C08F 110/06 Propene
• CPC Class Codes: C08F 210/06 Propene
• CPC Class Codes: C08F 2500/04 Broad molecular weight distribution, i.e. Mw/Mn > 6
• CPC Class Codes: C08F 2500/12 Melt flow index or melt flow ratio
• CPC Class Codes: C08F 2500/15 Isotactic
• CPC Class Codes: C08F 2500/17 Viscosity
• CPC Class Codes: C08F 2500/20 Activation energy or enthalpy
• CPC Class Codes: C08F 297/00 Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer
• CPC Class Codes: C08F 297/08 polymerising mono-olefins
• CPC Class Codes: C08F 297/083 the monomers being ethylene or propylene
• CPC Class Codes: C08F 4/6465 containing silicium
• CPC Class Codes: C08F 4/6567 and aluminium or compounds thereof
• CPC Class Codes: Y10S 526/904 Monomer polymerized in presence of transition metal containing catalyst at least part of which is supported on a polymer, e.g. prepolymerized catalysts

Abstract

The invention has an object to provide a catalyst for polymerizing or copolymerizing an α-olefin, catalyst constituent thereof, and method of polymerizing α-olefins with the catalyst, for production of α-olefin polymers or copolymers with high hydrogen response, high polymarization reaction rate, high stereoregularity and excellent melt fluidity. The invention discloses a catalyst constituent of the catalyst for polymerizing or copolymerizing an α-olefin, represented by Formula 37 or 38:
Si(OR¹)₃(NR²R³)Formula 37
(where in Formula 37, R¹ is a hydrocarbon group with 1 to 6 carbon atoms; R² is a hydrocarbon group with 1 to 12 carbon atoms or hydrogen; and R³ is a hydrocarbon group with 1 to 12 carbon atoms)
RNSi(OR¹)₃Formula 38
(where in Formula 38, R¹ is a hydrocarbon group with 1 to 6 carbon atoms; and RN is a cyclicl amino group).

Claims

1. A catalyst constituent of catalyst for polymerizing or copolymerizing an α

-olefin, represented by Formula 1;

Si(OR¹)₃(NR²R³) 

 

Formula 1

wherein in Formula 1, R¹ is an ethyl group;

R² is a hydrocarbon group with 1 to 12 carbon atoms or hydrogen; and

R³ is a hydrocarbon group with 1 to 12 carbon atoms.

2. The catalyst constituent of catalyst for polymerizing or copolymerizing an α

-olefin according to claim 1, wherein the compound represented by Formula 1 comprises one or more of;

dimethylaminotriethoxysilane;

diethylaminotriethoxysilane;

di-n-propylaminotriethyloxysilane;

methyl-n-propylaminotriethoxysilane;

t-butylaminotriethoxysilane;

ethyl-n-propylaminotriethoxysilane;

ethylisopropylaminotriethoxysilane; and

methylethylaminotriethoxysilane.

3. A catalyst for polymerizing or copolymerizing an α

-olefin, including the catalyst constituent according to claim 1.

4. A catalyst for polymerizing or copolymerizing an α

-olefin, including [A] a solid catalyst constituent consisting essentially of magnesium, titanium, a halogen element and an electron donor;

[B] an organoaluminum compound constituent; and

[C] the catalyst constituent according to claim 1.

5. An α

-olefin polymerization method of polymerizing or copolymerizing an α

-olefin in the presence of the catalyst for polymerizing or copolymerizing an α

-olefin, including the catalyst constituent of catalyst for polymerizing or copolymerizing an α

-olefin, represented by Formula 1;

Si(OR¹)₃(NR²R³) 

 

Formula 1

wherein in Formula 1, R¹ is an ethyl group;

R² is a hydrocarbon group with 1 to 12 carbon atoms or hydrogen; and

R³ is a hydrocarbon group with 1 to 12 carbon atoms.

6. A method of manufacturing α

-olefin propylene block copolymers, comprising a first step of homopolymerizing propylene in the presence of the catalyst for polymerizing or copolymerizing an α

-olefin, including the catalyst constituent of catalyst for polymerizing or copolymerizing an α

-olefin, represented by Formula 1;

Si(OR¹)₃(NR²R³) 

 

Formula 1

(wherein in Formula 1, R¹ is an ethyl group;

R² is a hydrocarbon group with 1 to 12 carbon atoms or hydrogen; and

R³ is a hydrocarbon group with 1 to 12 carbon atoms);

and a second step of block copolymerizing a combined monomer of propylene with an α

-olefin other than propylene in the presence of the same catalyst after the first step.

7. The method of manufacturing α

-olefin propylene block copolymers according to claim 6, wherein the second step includes gas-phase copolymerizing the combined monomer of propylene with the α

-olefin other than propylene without inactivation of the catalyst used in the first step.

8. The method of manufacturing α

-olefin propylene block copolymers according to claim 6, wherein the α

-olefin is ethylene.

9. The method of manufacturing α

-olefin propylene block copolymers according to claim 6, wherein the second step includes adding hydrogen in copolymerization.

10. A method of manufacturing α

-olefin propylene random copolymers, comprising random copolymerizing a combined monomer of propylene with an α

-olefin other than propylene in the presence of the catalyst for polymerizing or copolymerizing an α

-olefin, including the catalyst constituent of catalyst for polymerizing or copolymerizing an α

-olefin, represented by Formula 1;

Si(OR¹)₃(NR²R³) 

 

Formula 1

wherein in Formula 1, R¹ is an ethyl group;

R² is a hydrocarbon group with 1 to 12 carbon atoms or hydrogen; and

R³ is a hydrocarbon group with 1 to 12 carbon atoms.

11. The method of manufacturing α

-olefin propylene random copolymers according to claim 10, wherein the α

-olefin is ethylene.