EP0202946A2 — Alpha-olefin block copolymer particles and proces…

Claim 1

Independent Claim 208 words

A process for the production of a-olefin block copolymer particles which comprises (1) homopolymerizing propylene or copolymerising propylene with ethylene or an a-olefin having 4 to 6 carbon atoms in liquified propylene or in the gaseous phase, the resultant polymer containing not more than 6 mole % of ethylene or said a-olefin, (2) further reacting the polymer produced in step (1) by homopolymerizing ethylene or copolymerizing ethylene and propylene and optionally an a-olefin having 4 to 6 carbon atoms so that the ethylene content in the polymer produced in this step is not less than 10 mole % and that the polymer produced in this step amounts to 10 to 70 % by weight based on the weight of the whole polymer, said polymerization in steps (1) and (2) being carried out in the presence of a catalyst system comprising (A) a solid catalyst component containing at least titanium, chlorine and an electron-donating compund and having a pore volume in respect of pores having a radius of 200 to 15,000 A of not less than 0.08 cc/g, a mean particle size of 5 to 100 µm, and a geometric standard deviation (og) of the particle size distribution of not more than 2, and (B) an organic aluminum compound.

Claim 2

Dependent Claim 208 words

A process for the production of a-olefin block copolymer particles which comprises (1) homopolymerizing propylene or copolymerising propylene with ethylene or an a-olefin having 4 to 6 carbon atoms in liquified propylene or in the gaseous phase, the resultant polymer containing not more than 6 mole % of ethylene or said a-olefin, (2) further reacting the polymer produced in step (1) by homopolymerizing ethylene or copolymerizing ethylene and propylene and optionally an a-olefin having 4 to 6 carbon atoms so that the ethylene content in the polymer produced in this step is not less than 10 mole % and that the polymer produced in this step amounts to 10 to 70 % by weight based on the weight of the whole polymer, said polymerization in steps (1) and (2) being carried out in the presence of a catalyst system comprising (A) a solid catalyst component containing at least titanium, chlorine and an electron-donating compund and having a pore volume in respect of pores having a radius of 200 to 15,000 A of not less than 0.08 cc/g, a mean particle size of 5 to 100 µm, and a geometric standard deviation (og) of the particle size distribution of not more than 2, and (B) an organic aluminum compound.

Claim 3

Dependent Claim 106 words

A process for the production of a-olefin block copolymer particles according to claim 1, wherein the catalyst system is such that when it is subjected to the polymerization of propylene in liquefied propylene for 4 hours, the resulting polymer contains a component soluble in xylene at 20°C in an amount of not more than 5 % by weight, and the polymer is produced in an amount of not less than 6,000 g per 1 g of the solid catalyst component, and the polymer produced in the first step contains a component soluble in xylene at 20°C in an amount of not more than 15 by weight.

Claim 4

Dependent Claim 104 words

A process for the production of a-olefin block copolymer particles according to claim 1, wherein the catalyst system is such that when it is subjected to the polymerization of propylene in liquefied propylene for 4 hours, the resulting polymer contains a component soluble in xylene at 20°C of not more than 4 % by weight and the polymer is produced in an amount of not less than 6,000 g per 1 g of the solid catalyst component, and the polymer produced in the first step contains a component soluble in xylene at 20°C in an amount of not more than 5 % by weight.

Claim 5

Dependent Claim 202 words

A process for the production of a-olefin block copolymer particles according to any one of claims 1 to 3, wherein the catalyst system comprises (A) a solid catalyst component consisting essentially of a titanium compound carried on a magnesium compound and 1 to 20 % by weight of an electron donating compound selected from ether compounds and ester compounds, the solid catalyst component having a pore volume in respect of pores having a radius of 200 to 15,000 A of not less than 0.1 cc/g, a mean particle size of 10 to 75 pm, and a geometric standard deviation (σg) of the particle size distribution of not more than 1.8. (B) an organic aluminum compound of the formula: R e AlX 3-e , wherein R is a hydrocarbon group having 1 to 18 carbon atoms, X is a halogen atom, and 2.5 ≦ e ≦ 3, in an amount of 40 to 1,500 mole per mole of titanium in the solid catalyst component (A), and (C) an electron donor selected from the group consisting of esters, amines, and organic silicon compounds having a Si-0-C bond, in an amount of not more than 1 mole per mole of the organic aluminum compound (B).

Claim 6

Dependent Claim 163 words

A process for the production of a-olefin block copolymer particles according to claim 1, wherein the catalyst system comprises (A) a solid catalyst component comprising a titanium compound of the formula: Ti(OR 1 ) b Cl 3-b , wherein R 1 is a hydrocarbon group having 1 to 20 carbon atoms and 0.001 < b < 0.15, and 1 to 15 by weight of an ether compound, which has a pore volume in respect of pores having a radius of 200 to 15,000 A of not less than 0.1 cc/g, a mean particle size of 10 to 75 µm, and a geometric standard deviation (σg) of the particle size distribution of not more than 1.8, and (B) an organic aluminum compound of the formula: R 2 AlX, wherein R is a hydrocarbon group having 1 to 18 carbon atoms and X is a halogen atom, in an amount of 1 to 30 mole per mole of titanium in the solid catalyst component (A).

Claim 7

Dependent Claim 142 words

A process for the production of a-olefin block copolymer particles according to claim 1, wherein the catalyst system comprises (A) a solid catalyst component comprising a titanium trichloride having a layer structure and 1 to 15 % by weight of an ether compound, the solid catalyst component having a pore volume in respect of pores having a radius of 200 to 15,000 A of not less than 0.1 cc/g, a mean particle size of 10 to 75 µm, and a geometric standard deviation (ag) of the particle size distribution of not more than 1.8, and (B) an organic aluminum compound of the formula; R 2 AlX, wherein R is a hydrocarbon group having 1 to 18 carbon atoms and X is a halogen atom, in an amount of 1 to 30 mole per mole of titanium in the solid catalyst component (A).

Claim 8

Dependent Claim 135 words

An a-olefin block copolymer particle which comprises (a) a first segment consisting essentially of propylene alone or a combination of propylene and not more than 6 % by mole of ethylene and further optionally an a-olefin having 4 to 6 carbon atoms; (b) a second segment consisting essentially of ethylene alone or a combination of ethylene and not more than 90 % by mole of propylene and further optionally an a-olefin having 4 to 6 carbon atoms; said second segment being in a ratio of 10 to 70 % by weight based on whole weight of the copolymer; and has a mean particle size of 150 to 3,000 um, a geometric standard deviation (og) of the particle size distribution of not more than 2, and an adhesion force of not more than 6 g/cm .

Claim 9

Dependent Claim 135 words

An a-olefin block copolymer particle which comprises (a) a first segment consisting essentially of propylene alone or a combination of propylene and not more than 6 % by mole of ethylene and further optionally an a-olefin having 4 to 6 carbon atoms; (b) a second segment consisting essentially of ethylene alone or a combination of ethylene and not more than 90 % by mole of propylene and further optionally an a-olefin having 4 to 6 carbon atoms; said second segment being in a ratio of 10 to 70 % by weight based on whole weight of the copolymer; and has a mean particle size of 150 to 3,000 um, a geometric standard deviation (og) of the particle size distribution of not more than 2, and an adhesion force of not more than 6 g/cm .

Claim 10

Dependent Claim 32 words

An a-olefin block copolymer particle according to claim 7, wherein the first segment contains a component soluble in xylene at 20°C in am amount of not more than 15 % by weight.

Claim 11

Dependent Claim 32 words

An a-olefin block copolymer particle according to claim 8, wherein the first segment contains a component soluble in xylene at 20°C in an amount of not more than 5 % by weight.

Claim 12

Dependent Claim 25 words

An article comprising a copolymer produced by further processing, for example molding, of block copolymer particles according to any one of claims 7 to 9.

Alpha-olefin block copolymer particles and process for the production thereof

Abstract

Inventors

Bibliographic Details

Claims Analysis

References Cited (Backward Citations)

USPTO Annuity & Maintenance Windows

Assigned Categories & Tags

Assign Category Tag