Catalyst and process of polymerization of alpha-monoolefins

Claim 2

A process for the polymerization of at least one alpha-monoolefin monomer which comprises polymerizing said at least one alpha-monoolefin monomer under polymerization conditions employing the catalyst system consisting essentially of (A) a milled admixture of effective ratios of a titanium halide, anhydrous magnesium or manganous chloride, optionally, with a Lewis base, and (B) effective ratios of at least one dihydrocarbylaluminum halide, at least one dihydrocarbylaluminum hydride, and an ether-alcohol, employing catalytically effective ratios of said (A):(B).

Claim 3

The polymerization process according to claim 1 wherein said titanium halide is a di-, tri- or tetrahalide of titanium.

Claim 4

The polymerization process according to claim 2 wherein said titanium halide is represented by TiX 4-n R' n , wherein X is a halogen and is bromine, chlorine, or iodine, R' is an alkyl, cycloalkyl, cycloalkoxy, aryl, aryloxy, or alkoxy radical of 2 to 8 carbon atoms, and n is zero or an integer of 1, 2 or 3.

Claim 5

The polymerization process according to claim 3 wherein said titanium halide is titanium tetrachloride, trichloro-n-octyl titanium, dibromodimethyl titanium, iodotriethoxy titanium, trichlorophenoxytitanium, tribromocyclohexyltitanium, trichlorohexyloxytitanium, or mixture.

Claim 6

The polymerization process according to claim 2 wherein said Lewis base is an amine, amide, ether, carboxylic acid, ester, ketone, nitrile, or phosphine.

Claim 7

The polymerization process according to claim 5 wherein said Lewis base is an aliphatic carboxylic acid, aromatic carboxylic acid, alkylester of aliphatic carboxylic acid, alkylester of aromatic carboxylic acid, aliphatic ether, aromatic ether, aliphatic ketone, aromatic ketone, aliphatic aldehyde, aliphatic alcohol, aromatic alcohol, aliphatic acid halide, aliphatic nitrile, aromatic nitrile, aliphatic, amine, aromatic amine, aliphatic phosphine, aromatic phosphine, amide, combination, or a mixture.

Claim 8

The polymerization process according to claim 6 wherein said Lewis base is an ester, wherein said ester is an ester of an aliphatic alcohol with an aromatic carboxylic acid represented by the formula: ##STR8## wherein R 3 is an alkyl group of 1 to 4 carbon atoms, R 4 is a para-substituent on the ring and is a monovalent radical selected from --F, --Cl, --Br, --I, --OH, --OR 2 , --OOCR 2 , --SH, --NH 2 , --NHR 2 , --NR 2 2 , --NHCOR 2 , --NR 2 COR 2 , NO 2 , --CN, --CHO, --COR 2 , --COOR 2 , --CONH 2 , CONR 2 2 , --SO 2 R 2 , --CX' 3 wherein X'=F, Cl, Br, I or hydrogen, and wherein R 2 is a hydrocarbon radical selected from alkyl, cycloalkyl, and aryl of up to 12 carbon atoms.

Claim 9

The polymerization process according to claim 7 wherein said Lewis base is triethylamine, triphenylamine, diphenylamine, acetamide, butyramide, acetanilide, acetic acid, benzoic acid, dimethyl ether, diethyl ether, ethylbutylether, diphenyl ether, acetone, methyl n-butyl ketone, acetophenone, acetonitrile, iosbutyronitrile, benzonitrile, tributylphosphine propyl-(n-pentyl)phosphine, triphenylphosphine, ethyl benzoate, ethyl anisate (p-methoxybenzoate), ethyl p-dimethylaminobenzoate, ethyl p-fluorobenzoate, ethyl p-cyanobenzoate, methyl benzoate, isopropyl p-diethylaminobenzoate, butyl p-fluorobenzoate, n-propyl p-cyanobenzoate, ethyl p-trifluoromethylbenzoate, methyl p-hydroxybenzoate, ethyl p-methoxycarbonylbenzoate, methyl p-acetylbenzoate, isopropyl p-formylbenzoate, methyl p-nitrobenzoate, ethyl p-carbamoylbenzoate, methyl p-mercaptobenzoate, methyl-p-chlorobenzoate, n-butyl-p-bromobenzoate, isopropyl-p-iodobenzoate, ethyl-p-aminobenzoate, n-propyl-p-methylaminobenzoate, methyl-p-acetamidobenzoate, n-butyl-p-formylbenzoate, dimethyl terephthalate, ethyl-p-(N,N-dimethylcarbamoyl)benzoate, n-propyl-p-(methylsulfonyl)benzoate, methyl-p-trifluoromethylbenzoate, ethyl-p-acetoxybenzoate, or mixtures thereof.

Claim 10

The polymerization process according to claim 8 wherein said Lewis base is ethyl anisate or ethylbenzoate.

Claim 11

The polymerization process according to claim 2 wherein said (B) dihydrocarbylaluminum compounds are represented by AlR 2 5 X', wherein R 5 is an alkyl radical of 1 to 12 carbon atoms, and X' is fluorine, chlorine, bromine, iodine or hydrogen.

Claim 12

The polymerization process according to claim 10 wherein said dihydrocarbylaluminum compounds are selected from the group consisting of dimethylaluminum bromide, diethylaluminum chloride, diisopropylaluminum iodide, diisobutylaluminum hydride, di-(2-ethylhexyl)aluminum chloride, di-n-dodecylaluminum hydride, such that said (B) component includes at least one halide and at least one hydride.

Claim 13

The polymerization process according to claim 2 employing a molar ratio of about 0.5:1 to 4:1 titanium halide:Lewis base in said component (A).

Claim 14

The polymerization process according to claim 2 wherein said etheralcohol is a monoalkyl ether of ethylene glycol or diethylene glycol, wherein the alkyl groups each contains 1 to 4 carbon atoms.

Claim 15

The polymerization process according to claim 13 wherein said etheralcohol is 2-methoxyethanol, 2-ethoxyethanol, 2-n-butoxyethanol, 2-(2-methoxyethoxy)ethanol, 2-(2-ethoxyethoxy)ethanol, 2-(2-n-butoxyethoxy)ethanol, and mixtures.

Claim 16

The polymerization process according to claim 2 employing an atom ratio of aluminum in the dihydrocarbylaluminum hydride plus the dihydrocarbyl aluminum halide to the titanium of about 10:1 to 250:1, and a mole ratio of dihydrocarbylaluminum hydride plus dihydrocarbylaluminum halide to the ether-alcohol of about 0.5:1 to 10:1.

Claim 17

The polymerization process according to claim 15 employing an atom ratio of aluminum in the dihydrocarbylaluminum hydride plus the dihydrocarbylaluminum halide to the titanium of about 25:1 to 150:1; and a mole ratio of dihydrocarbylaluminum hydride plus dihydrocarbylaluminum halide to the etheralcohol of about 1:1 to 5:1.

Claim 18

The polymerization process according to claim 16 wherein said etheralcohol is 2-(2-n-butoxyethoxy)ethanol.

Claim 19

The polymerization process according to claim 16 wherein said manganous or magnesium chloride is magnesium chloride, said catalyst includes said Lewis base, said Lewis base is an ester and is ethylanisate, said titanium halide is titanium tetrachloride, said dihydrocarbylaluminum halide is diethylaluminum chloride, said dihydrocarbylaluminum hydride is diisobutylaluminum hydride, and said ether-alcohol is diethyleneglycolmonobutyl ether.

Claim 20

The polymerization process according to claim 16 wherein said manganous or magnesium chloride is magnesium chloride, said catalyst includes said Lewis base and Lewis base is an ester and is ethylbenzoate, and said titanium halide is titanium tetrachloride, said ether-alcohol is diethyleneglycol monobutyl ether, said dihydrocarbyl chloride is diethylaluminum chloride, and said dihydrocarbyl aluminum hydride is diisobutylaluminum hydride.

Claim 21

The process according to claim 1 wherein said aliphatic alpha-monoolefin is represented by RCH═CH 2 wherein R is hydrogen or an alkyl radical.

Claim 22

The process according to claim 20 wherein said alpha-monoolefin monomer is ethylene, propylene, butene-1, isobutylene, 3-methylbutene-1, pentene-1, hexene-1, octene-1, or admixture thereof.

Claim 23

The process according to claim 21 employing a ratio of about 0.001 to 1 weight percent catalyst component (A) relative to the total reaction mixture including catalyst and alpha-monoolefin, and further including diluent where employed.

Claim 24

The process according to claim 22 wherein said polymerization is conducted under polymerization conditions at a temperature in the range of about -80° C. to +150° C.

Claim 25

The process according to claim 23 further incorporating a diluent selected from n-butane, isobutane, pentane, n-hexane, n-heptane, n-octane, cyclohexane, methylcyclohexane, cyclohexane, or a mixture.

Claim 26

The process according to claim 23, further employing minor amounts of hydrogen during polymerization effective to exercise control of molecular weight of the polymer.

Claim 27

The process according to claim 22 wherein said (A) is titanium tetrachloride, magnesium chloride, and ethyl benzoate or ethyl anisate, and said (B) is diethylaluminum chloride, diisobutylaluminum hydride, and butyl Carbitol.

Claim 28

The process according to claim 26 wherein said monomer is ethylene, or ethylene with another said alpha-monoolefin.

Claim 29

The process according to claim 26 wherein said monomer is propylene.