US4192772A — Solid catalyst and process for the preparation th…

Claim 1

Independent Claim 196 words

In a solid catalyst complex comprising the reaction product formed from reacting together (1) at least one magnesium compound (M) selected from oxygen-containing organic compounds of magnesium and halogen containing compounds of magnesium; with (2) at least one titanium compound (T) selected from oxygen-containing organic compounds of titanium and halogen containing compounds of titanium; with (3) at least one zirconium compound (Z) selected from oxygen-containing organic compounds of zirconium and halogen containing compounds of zirconium; and with (4) at least one aluminum halide (A) of the formula AlR' n X 3-n wherein R' is a C 1 -C 20 hydrocarbon, X is a halogen and n is a number such that O≦n≦3: said oxygen containing organic compounds of magnesium, titanium and zirconium contain at least one metal-oxygen-organic radical sequence and the organic radicals contain from 1 to 20 carbon atoms; said halogen-containing compounds of magnesium, titanium, and zirconium contain at least one halogen to metal bond sequence; the improvement wherein said compounds (M), (T), (Z) and (A) are used in amounts that satisfies the equation (Zr/Ti).(X/Mg+Zr+Ti)>3 where Mg, Zr, Ti and X represent the amounts, in gram-equivalents, of magnesium, zirconium, titanium and halogen of said compounds.

Claim 2

Dependent Claim 196 words

In a solid catalyst complex comprising the reaction product formed from reacting together (1) at least one magnesium compound (M) selected from oxygen-containing organic compounds of magnesium and halogen containing compounds of magnesium; with (2) at least one titanium compound (T) selected from oxygen-containing organic compounds of titanium and halogen containing compounds of titanium; with (3) at least one zirconium compound (Z) selected from oxygen-containing organic compounds of zirconium and halogen containing compounds of zirconium; and with (4) at least one aluminum halide (A) of the formula AlR' n X 3-n wherein R' is a C 1 -C 20 hydrocarbon, X is a halogen and n is a number such that O≦n≦3: said oxygen containing organic compounds of magnesium, titanium and zirconium contain at least one metal-oxygen-organic radical sequence and the organic radicals contain from 1 to 20 carbon atoms; said halogen-containing compounds of magnesium, titanium, and zirconium contain at least one halogen to metal bond sequence; the improvement wherein said compounds (M), (T), (Z) and (A) are used in amounts that satisfies the equation (Zr/Ti).(X/Mg+Zr+Ti)>3 where Mg, Zr, Ti and X represent the amounts, in gram-equivalents, of magnesium, zirconium, titanium and halogen of said compounds.

Claim 3

Dependent Claim 17 words

The solid catalyst complex of claim 1 wherein the equation (Zr/Ti).(X/Mg+Zr+Ti) has a value greater than 3.5.

Claim 4

Dependent Claim 23 words

The solid catalyst complex of claim 1 wherein the equation (X/Mg+Zr+Ti)>1 further defines the amount of compounds (M), (T), (Z) and (A) used.

Claim 5

Dependent Claim 21 words

The solid catalyst complex of claim 1 wherein the equation Zr/Ti>0.1 further defines the amount of compounds (T) and (Z) used.

Claim 6

Dependent Claim 32 words

The solid catalyst complex of claim 1 wherein the compounds (M), (T), (Z) and (A) are each used in amounts such that the equations 3.5<(Zr/Ti).(X/Mg+Zr+Ti)<80 (2) 1.5<X/Mg+Zr+Ti<10 (b) and 0.5<Zr/Ti<5 are satisfied.

Claim 7

Dependent Claim 67 words

The solid catalyst complex of claim 5 wherein the equation (a) has a value of from greater than 4 to less than 40; equation (b) has value of from greater than 2 to less than 8; equation (c) has a value of from greater than 0.5 to less than 5 and the amounts of compounds (M), (Z) and (T) are such that the equation 0.5<Ti+Zr/Mg<5 is satisfied.

Claim 8

Dependent Claim 17 words

The catalyst complex of claim 1 wherein the compound (M) is selected from magnesium alkoxides and phenoxides.

Claim 9

Dependent Claim 18 words

The catalyst complex of claim 1 wherein the compound (M) contains at least one Mg to Cl bond.

Claim 10

Dependent Claim 14 words

The catalyst complex of claim 1 wherein the compound (T) is TiCl 4 .

Claim 11

Dependent Claim 12 words

The catalyst complex of claim 1 wherein compound (T) is titanium tetraalkoxide.

Claim 12

Dependent Claim 15 words

The catalyst complex of claim 1 wherein compound (Z) is an alkoxide of tetravalent zirconium.

Claim 13

Dependent Claim 13 words

The catalyst complex of claim 1 wherein compound (Z) is ZrCl 4 .

Claim 14

Dependent Claim 65 words

The catalyst complex of claim 1 wherein compound (M) is selected from magnesium alkoxide and phenoxide; compound. (T) is selected from titanium tetrachloride and titanium tetraalkoxides; compound (Z) is selected from tetraalkoxides, tetrachlorides and alkoxychlorides of zirconium; and compound (A) corresponds to the formula AlR' n X 3-n wherein R' is a C 1 to C 6 hydrocarbon, X is chlorine and n is 1.

Claim 15

Dependent Claim 34 words

A catalyst for the polymerization of α-olefins comprising an organic-metallic compound of a metal of Groups Ia, IIa, IIb, IIIb and IVb of the Periodic Table and the solid catalyst complex of claim 1.

Claim 16

Dependent Claim 34 words

A catalyst for the polymerization of α-olefins comprising an organic-metallic compound of a metal of Groups Ia, IIa, IIb, IIIb and IVb of the Periodic Table and the solid catalyst complex of claim 13.

Claim 17

Dependent Claim 175 words

In a process for the preparation of a solid catalyst complex comprising reacting with one another the reactants comprising (1) at least one magnesium compound (M) selected from oxygen-containing organic compounds of magnesium and halogen containing compounds of magnesium; with (2) at least one titanium compound (T) selected from oxygen-containing organic compounds of titanium and halogen containing compounds of titanium; with (3) at least one zirconium compound (Z) selected from oxygen-containing organic compounds of zirconium and halogen containing compounds of zirconium; and with (4) at least one aluminum halide (A); p1 said oxygen containing organic compounds of magnesium, titanium and zirconium contain at least one metal-oxygen-organic radical sequence and the organic radicals contain from 1 to 20 carbon atoms; said halogen-containing compounds of magnesium, titanium and zirconium contain at least one halogen to metal bond sequence; the improvement wherein said compounds (M), (T), (Z) and (A) are used in amounts that satisfies the equation (Zr/Ti).(X/Mg+Zr+Ti)>3 where Mg, Zr, Ti and X represent the amounts, in gram-equivalents, of magnesium, zirconim, titanium and halogen of said compounds.

Claim 18

Dependent Claim 175 words

In a process for the preparation of a solid catalyst complex comprising reacting with one another the reactants comprising (1) at least one magnesium compound (M) selected from oxygen-containing organic compounds of magnesium and halogen containing compounds of magnesium; with (2) at least one titanium compound (T) selected from oxygen-containing organic compounds of titanium and halogen containing compounds of titanium; with (3) at least one zirconium compound (Z) selected from oxygen-containing organic compounds of zirconium and halogen containing compounds of zirconium; and with (4) at least one aluminum halide (A); p1 said oxygen containing organic compounds of magnesium, titanium and zirconium contain at least one metal-oxygen-organic radical sequence and the organic radicals contain from 1 to 20 carbon atoms; said halogen-containing compounds of magnesium, titanium and zirconium contain at least one halogen to metal bond sequence; the improvement wherein said compounds (M), (T), (Z) and (A) are used in amounts that satisfies the equation (Zr/Ti).(X/Mg+Zr+Ti)>3 where Mg, Zr, Ti and X represent the amounts, in gram-equivalents, of magnesium, zirconim, titanium and halogen of said compounds.

Claim 19

Dependent Claim 40 words

The process according to claim 16 wherein the reactants (1) to (3) are selected from oxygen-containing organic compounds, reactant (1) is added to a mixture of reactants (2) and (3) and then reactant (4) is added to the resultant mixture.

Claim 20

Dependent Claim 48 words

Process according to claim 16, wherein the reactants (1) and (2) are selected from oxygen-containing organic compounds, the reactant (3) is selected from halogen-containing compounds and reactant (3) is added to a mixture of reactants (1) and (2) and then reactant (4) is added to the resultant mixture.

Claim 21

Dependent Claim 38 words

Process according to claim 16, wherein the reactants (1) and (3) are selected from oxygen-containing organic compounds, reactant (2) is selected from halogen-containing compounds and reactant (2) is added to a mixture of reactants (1), (3) and (4).

Claim 22

Dependent Claim 39 words

The process of claim 16 wherein the aluminum halide is represented by the formula AlR' n X 3-n wherein R' is a C 1 -C 20 hydrocarbon, X is a halogen and n is any number such that O<n<3.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1983-03-11	1983-09-10	1984-03-11	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1987-03-11	1987-09-10	1988-03-11	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1991-03-11	1991-09-10	1992-03-11	$7700.00	Window Closed / Lapsed

Solid catalyst and process for the preparation thereof

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