US4368304A — Process for producing α-olefin polymers

Claim 1

Independent Claim 182 words

A process for producing α-olefin polymers which comprises: reacting one mole of an organoaluminum compound with 0.1 to 8 mols of an electron donor in a solvent at a temperature of -20° to 200° C., to obtain a reaction product (I); reacting this reaction product (I) with TiCl 4 at a temperature of 10° to 90° C. in a ratio of the number of Al atoms to that of Ti atoms of 0.05 to 10, and thereafter removing a liquid portion from the resulting material followed by washing to thereby obtain a solid product (II) having no free TiCl 4 ; reacting 100 g of this solid product (II) with 10 to 1,000 g of an electron donor and 10 to 1,000 g of an electron acceptor at a temperature of 40° C. to 200° C. to obtain a solid product (III); and polymerizing an α-olefin or α-olefins in the presence of a catalyst comprising a combination of said solid product (III) with an organoaluminum compound, said catalyst being a preliminarily activated one obtained by further reacting an α-olefin with said combination.

Claim 2

Dependent Claim 182 words

A process for producing α-olefin polymers which comprises: reacting one mole of an organoaluminum compound with 0.1 to 8 mols of an electron donor in a solvent at a temperature of -20° to 200° C., to obtain a reaction product (I); reacting this reaction product (I) with TiCl 4 at a temperature of 10° to 90° C. in a ratio of the number of Al atoms to that of Ti atoms of 0.05 to 10, and thereafter removing a liquid portion from the resulting material followed by washing to thereby obtain a solid product (II) having no free TiCl 4 ; reacting 100 g of this solid product (II) with 10 to 1,000 g of an electron donor and 10 to 1,000 g of an electron acceptor at a temperature of 40° C. to 200° C. to obtain a solid product (III); and polymerizing an α-olefin or α-olefins in the presence of a catalyst comprising a combination of said solid product (III) with an organoaluminum compound, said catalyst being a preliminarily activated one obtained by further reacting an α-olefin with said combination.

Claim 3

Dependent Claim 21 words

A process according to claim 1 wherein said α-olefin polymerization is carried out by slurry polymerization followed by gas phase polymerization.

Claim 4

Dependent Claim 21 words

A process according to claim 1 wherein said α-olefin polymerization is carried out by bulk polymerization followed by gas phase polymerization.

Claim 5

Dependent Claim 52 words

A process according to claim 1 wherein said organoaluminum compound has the general formula AlR.sub.n R'.sub.n' X.sub.3-(n+n') wherein R and R' each represent alkyl, aryl, alkaryl, cycloalkyl or alkoxy group; X represents fluorine, chlorine, bromine or iodine; and n and n' each represent a number which must satisfy a relationship of 0<n+n'≦3.

Claim 6

Dependent Claim 52 words

A process according to claim 1 wherein said electron donors may be the same or different and are each at least one member selected from the group consisting of ethers, alcohols, esters, aldehydes, fatty acids, aromatic acids, ketones, nitriles, amines, amides, urea, thiourea, isocyanates, azo compounds, phosphines, phosphites, phosphinites, thioethers and thioalcohols.

Claim 7

Dependent Claim 34 words

A process according to claim 1 wherein said electron donors may be the same or different and are composed singly or mainly of ethers and those other than ethers are employed together with ethers.

Claim 8

Dependent Claim 52 words

A process according to claim 1 wherein said electron acceptor is at least one member selected from the group consisting of anhydrous AlCl 3 , SiCl 4 , SnCl 2 , SnCl 4 , TiCl 4 , ZrCl 4 , PCl 3 , PCl 5 , VCl 4 and SbCl 5 .

Claim 9

Dependent Claim 13 words

A process according to claim 1 wherein said solvent is an aliphatic hydrocarbon.

Claim 10

Dependent Claim 29 words

A process according to claim 1 wherein said reaction of said sold product (II) with an electron donor and an electron acceptor is carried out in an aliphatic hydrocarbon.

Claim 11

Dependent Claim 68 words

A process according to claim 1 wherein said reaction of said solid product (II) with an electron donor and an electron acceptor is carried out by reacting said electron donor with said electron acceptor in advance at a temperature of 10° to 100° C. for a time of 30 minutes to 2 hours; cooling the resulting reaction product; and reacting this reaction product with said solid product (II).

Claim 12

Dependent Claim 184 words

A process for producing α-olefin polymers which comprises: reacting one mole of an organoaluminum compound with 1 to 4 mols of an electron donor in 0.5 to 5 l of a solvent of an aliphatic hydrocarbon at a temperature of -10° to 100° C., to obtain a reaction product (I); reacting this reaction product (I) with TiCl 4 at a temperature of 10° to 90° C. in a ratio of the number of Al atoms to that of Ti atoms of 0.06 to 0.2, and thereafter removing a liquid portion from the resulting material followed by washing, to obtain a solid product (II) having no free TiCl 4 ; reacting 100 g of this solid product (II) with 50 to 200 g of an electron donor and 20 to 500 g of an electron acceptor in 0.1 to 1 l of a solvent of an aliphatic hydrocarbon at a temperature of 50° to 100° C. to obtain a solid product III; and polymerizing α-olefin or α-olefins in the presence of a catalyst comprising a combination of said solid product (III) with an organoaluminum compound.

Claim 13

Dependent Claim 184 words

A process for producing α-olefin polymers which comprises: reacting one mole of an organoaluminum compound with 1 to 4 mols of an electron donor in 0.5 to 5 l of a solvent of an aliphatic hydrocarbon at a temperature of -10° to 100° C., to obtain a reaction product (I); reacting this reaction product (I) with TiCl 4 at a temperature of 10° to 90° C. in a ratio of the number of Al atoms to that of Ti atoms of 0.06 to 0.2, and thereafter removing a liquid portion from the resulting material followed by washing, to obtain a solid product (II) having no free TiCl 4 ; reacting 100 g of this solid product (II) with 50 to 200 g of an electron donor and 20 to 500 g of an electron acceptor in 0.1 to 1 l of a solvent of an aliphatic hydrocarbon at a temperature of 50° to 100° C. to obtain a solid product III; and polymerizing α-olefin or α-olefins in the presence of a catalyst comprising a combination of said solid product (III) with an organoaluminum compound.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1986-01-10	1986-07-12	1987-01-11	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1990-01-10	1990-07-12	1991-01-11	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1994-01-10	1994-07-12	1995-01-11	$7700.00	Window Closed / Lapsed

Process for producing α-olefin polymers

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