Process for producing propylene-ethylene block copolymers

Claim 1

In a process for producing propylene-ethylene block copolymer which comprises, in a first stage initiating polymerization of propylene alone or with a minor amount of ethylene in the substantial absence of an inert solvent and continuing the polymerization in liquified monomer or in the gas phase so that the ethylene content in the polymer produced in the first stage is not more than about 4% by weight to produce crystalline polypropylene accounting for about 60 to 95% by weight of the final block copolymer and, subsequently, in the second stage, randomly copolymerizing propylene and ethylene in liquified monomer or in the gas phase or polymerizing ethylene alone in the gas phase so that the ethylene content in the polymer block produced in the second stage is 10% by weight or more to produce an ethylene-propylene copolymer block or an ethylene homopolymer block accounting for 5 to 40% by weight of the final block copolymer, in the presence of a catalyst system, wherein said polymerization is carried out at a temperature of 0° to 90° C. under a pressure at which the monomer is present in the liquid form or is carried out in a gas phase at a temperature below the softening point of the polymer product under a pressure of about atmospheric pressure to 60 kg/cm 2 , the improvement which comprises said catalyst system comprising: a titanium trichloride solid catalyst component obtained by (a) reacting (i) a reduced product obtained by reducing titanium tetrachloride with an organoaluminum compound of the formula R' n AlX' 3-n , wherein R' represents a straight chain or branched chain alkyl group, an alicyclic group or an aryl group each having up to 18 carbon atoms, X' represents a halogen atom or a hydrogen atoms and n is a number 1≦n≦3, (ii) a heat treated solid obtained by heat treating the reduced product (i) in the presence or absence of an inert hydrocarbon solvent at a temperature of about 50° to 120° C., or (iii) a reaction product obtained by further reacting the reduced product (i) with an aluminum compound of the formula R" pAlX 3-p , wherein R" represents a straight chain or branched chain alkyl group, an alicyclic group or an aryl group each having up to 18 carbon atoms, X represents a halogen atom and p is a number 1≦p≦1.5; with a mixture of halogen or a halogen compound and an ether; (b) reacting (i) a reduced product obtained by reducing titanium tetrachloride with an organoaluminum compound of the formula R' n AlX' 3-n , wherein R' represents a straight chain or branched chain alkyl group, an alicyclic group or an aryl group each having up to 18 carbon atoms, X' represents a halogen atom or a hydrogen atom and n is a number 1≦n≦3, or (ii) a heat treated solid obtained by heat treating the reduced product (i) in the presence or absence of an inert solvent at a temperature of 20° to 100° C., with an ether and then reacting the ether-treated solid with titanium tetrachloride, or further reacting the resulting product with a mixture of halogen or halogen compound and an ether; or (c) reducing titanium tetrachloride with an organoaluminum compound of the formula R' n AlX' 3-n , wherein R' represents a straight chain or branched chain alkyl group, an alicyclic group or an aryl group each having 1 to 18 carbon atoms, X' represents a halogen atom or a hydrogen atom and n is a number 1≦n≦3, reacting the reduced product with an ether compound, and then reacting the ether treated compound with an aluminum compound of the formula R"pALX 3-p , wherein R" represents a straight chain or branched chain alkyl group, an alicyclic group, or an aryl group, each having 1 to 18 carbon atoms, X represents a halogen atom and p is a number 1≦p≦1.5 and further reacting said product with an ether or a mixture of a halogen or a halogen compound and an ether, [B] an organoaluminum compound of the formula R m AlY 3-m , wherein R represents a straight chain or branched chain alkyl group having 1 to 8 carbon atoms, Y represents a halogen atom or a hydrgen atom or an alkoxy group and m is a number 2≦m≦3, and, optionally, [C] an electron donor as a third component, selected from the group consisting of amines, ethers, esters, derivatives of sulfur, halogens, benzene, azulene, organic or inorganic nitrogen and phosphorus compounds, said component [B] being used in concentration of about 0.05 to 50 m mol per mol of the monomer, the molar ratio of [B] to [A] being about 1/1 to 500/1, the molar ratio of [C] to [A] being about 0.1 to 10 when [C] is used, and said catalyst [A] being used to produce at least 8,000 g block copolymer per gram of solid catalyst.