US4849389A — Catalyst composition for polymerizing alpha-olefi…

Claim 1

Independent Claim 141 words

A process for preparing a supported alpha-olefin polymerization catalyst composition which comprises the steps of: (i) contacting a slurry of a solid, porous carrier and a non-polar solvent with at least one organomagnesium composition having the formula R.sub.m Mg R.sub.n ' (I) where R and R' are the same or different C 4 -C 12 alkyl groups, m and n are each 0, 1 or 2, provided that m+n is equal to the valence of Mg; (ii) contacting the slurry of step (i) with at least one compound of the formula R"--OH (II) where R" is a C 1 -C 10 alkyl group or a C 1 -C 10 halogenated alkyl group; (iii) contacting the slurry of step (ii) with at least one transition metal compound soluble in the non-polar solvent; and (iv) combining the product of step (iii) with trimethylaluminum.

Claim 2

Dependent Claim 141 words

A process for preparing a supported alpha-olefin polymerization catalyst composition which comprises the steps of: (i) contacting a slurry of a solid, porous carrier and a non-polar solvent with at least one organomagnesium composition having the formula R.sub.m Mg R.sub.n ' (I) where R and R' are the same or different C 4 -C 12 alkyl groups, m and n are each 0, 1 or 2, provided that m+n is equal to the valence of Mg; (ii) contacting the slurry of step (i) with at least one compound of the formula R"--OH (II) where R" is a C 1 -C 10 alkyl group or a C 1 -C 10 halogenated alkyl group; (iii) contacting the slurry of step (ii) with at least one transition metal compound soluble in the non-polar solvent; and (iv) combining the product of step (iii) with trimethylaluminum.

Claim 3

Dependent Claim 16 words

A process of claim 1 wherein R and R' are C 4 -C 10 alkyl groups.

Claim 4

Dependent Claim 16 words

A process of claim 2 wherein R and R' are C 4 -C 8 alkyl groups.

Claim 5

Dependent Claim 20 words

A process of claim 3 wherein R and R' are each butyl groups, m is 1 and n is 1.

Claim 6

Dependent Claim 19 words

A process of claim 4 wherein the non-polar solvent is a hydrocarbon which is a liquid at ambient conditions.

Claim 7

Dependent Claim 15 words

A process of claim 5 wherein R" is a C 1 -C 8 alkyl group.

Claim 8

Dependent Claim 15 words

A process of claim 6 wherein R" is a methyl, ethyl, propyl or butyl group.

Claim 9

Dependent Claim 17 words

A process of claim 7 wherein the transition metal compound is a compound of titanium or vanadium.

Claim 10

Dependent Claim 13 words

A process of claim 8 wherein the transition metal compound is titanium halide.

Claim 11

Dependent Claim 12 words

A process of claim 9 wherein the titanium halide is titanium tetrahalide.

Claim 12

Dependent Claim 13 words

A process of claim 10 wherein the titanium tetrahalide is TiCl 4 .

Claim 13

Dependent Claim 33 words

A process of claim 10 wherein the amount of the TiCl 4 present in said step (iii) is such that the molar ratio of Mg to Ti is about 1 to about 3.

Claim 14

Dependent Claim 33 words

A process of claim 12 wherein the amount of the TiCl 4 present in said step (ii) is such that the molar ratio of Mg to Ti is about 2 to about 3.

Claim 15

Dependent Claim 13 words

A process of claim 13 wherein the solid, porous carrier contains OH groups.

Claim 16

Dependent Claim 31 words

A process of claim 14 wherein the amount of the organomagnesium composition used in said step (i) is such that the molar ratio of Mg:OH is about 1:1 to about 6:1.

Claim 17

Dependent Claim 31 words

A process of claim 15 wherein the amount of the organomagnesium composition used in said step (i) is such that the molar ratio of Mg-OH is about 2:1 to about 4:1.

Claim 18

Dependent Claim 31 words

A process of claim 16 wherein the amount of the organomagnesium composition used in said step (i) is such that the molar ratio of Mg:OH is about 2.1:1 to about 3.5:1.

Claim 19

Dependent Claim 28 words

A process of claim 17 wherein the amount of the organomagnesium composition used in said step (i) is such that the molar ratio of Mg:OH is about 3:1.

Claim 20

Dependent Claim 36 words

A process of claim 18 wherein the solid, porous carrier is silica which, prior to contact thereof with the solvent in step (i), is heated at a temperature of about 100° C. to about 1000° C.

Claim 21

Dependent Claim 17 words

A process of claim 19 wherein the silica is heated at a temperature of about 800° C.

Claim 22

Dependent Claim 37 words

A process of claim 20 wherein the silica has, after the heating, surface hydroxyl group concentration of about 0.5 mmoles/gr, a surface area of 300 m 2 /gram and a pore volume of 1.65 m 3 /gram.

Claim 23

Dependent Claim 33 words

A process of claim 21 wherein the product of said step (iii), prior to conducting said step (iv), is dried at about 40° to about 65° C. to substantially remove the non-polar solvent.

Claim 24

Dependent Claim 134 words

A supported alpha-olefin polymerization catalyst composition prepared by: (i) contacting a slurry of a solid, porous carrier and a non-polar solvent with at least one organomagnesium composition having the formula R Mg R' (I) where R and R' are the same or different C 4 -C 12 alkyl groups, m and n are each 0, 1 or 2, provided that m+n is equal to the valence of Mg; (ii) contacting the slurry of step (i) with at least one compound of the formula R"--OH (II) where R" is a C 1 -C 10 alkyl group or a C 1 -C 10 halogenated alkyl group; (iii) contacting the slurry of step (ii) with at least one transition metal compound soluble in the non-polar solvent; and (iv) combining the product of step (iii) with trimethyl aluminum.

Claim 25

Dependent Claim 134 words

A supported alpha-olefin polymerization catalyst composition prepared by: (i) contacting a slurry of a solid, porous carrier and a non-polar solvent with at least one organomagnesium composition having the formula R Mg R' (I) where R and R' are the same or different C 4 -C 12 alkyl groups, m and n are each 0, 1 or 2, provided that m+n is equal to the valence of Mg; (ii) contacting the slurry of step (i) with at least one compound of the formula R"--OH (II) where R" is a C 1 -C 10 alkyl group or a C 1 -C 10 halogenated alkyl group; (iii) contacting the slurry of step (ii) with at least one transition metal compound soluble in the non-polar solvent; and (iv) combining the product of step (iii) with trimethyl aluminum.

Claim 26

Dependent Claim 17 words

A catalyst composition of claim 23 wherein R and R' are C 4 -C 10 alkyl groups.

Claim 27

Dependent Claim 17 words

A catalyst composition of claim 24 wherein R and R' are C 4 -C 8 alkyl groups.

Claim 28

Dependent Claim 21 words

A catalyst composition of claim 25 wherein R and R' are each butyl groups, m is 1 and n is 1.

Claim 29

Dependent Claim 20 words

A catalyst composition of claim 26 wherein the non-polar solvent is a hydrocarbon which is a liquid at ambient conditions.

Claim 30

Dependent Claim 16 words

A catalyst composition of claim 27 whrein R" is a C 1 -C 8 alkyl group.

Claim 31

Dependent Claim 16 words

A catalyst composition of claim 28 wherein R" is a methyl, ethyl, propyl or butyl group.

Claim 32

Dependent Claim 18 words

A catalyst composition of claim 29 wherein the transition metal compound is a compound of titanium or vanadium.

Claim 33

Dependent Claim 14 words

A catalyst composition of claim 30 wherein the transition metal compound is titanium halide.

Claim 34

Dependent Claim 13 words

A catalyst composition of claim 31 wherein the titanium halide is titanium tetrahalide.

Claim 35

Dependent Claim 14 words

A catalyst composition of claim 32 wherein the titanium tetrahalide is TiCl 4 .

Claim 36

Dependent Claim 34 words

A catalyst composition of claim 33 wherein the amount of the TiCl 4 present in said step (iii) is such that the molar ratio of Mg to Ti is about 1 to about 3.

Claim 37

Dependent Claim 34 words

A catalyst composition of claim 34 wherein the amount of the TiCl 4 present in said step (iii) is such that the molar ratio of Mg to Ti is about 2 to about 3.

Claim 38

Dependent Claim 14 words

A catalyst composition of claim 35 wherein the solid, porous carrier contains OH groups.

Claim 39

Dependent Claim 32 words

A catalyst composition of claim 36 wherein the amount of the organomagnesium composition used in said step (i) is such that the molar ratio of Mg:OH is about 1:1 to about 6:1.

Claim 40

Dependent Claim 32 words

A catalyst composition of claim 37 wherein the amount of the organomagnesium composition used in said step (i) is such that the molar ratio of Mg:OH is about 2:1 to about 4:1.

Claim 41

Dependent Claim 32 words

A catalyst composition of claim 38 wherein the amount of the organomagnesium composition used in said step (i) is such that the molar ratio of Mg:OH is about 2.5:1 to about 3.5:1.

Claim 42

Dependent Claim 29 words

A catalyst composition of claim 39 wherein the amount of the organomagnesium composition used in said step (i) is such that the molar ratio of Mg:OH is about 3:1.

Claim 43

Dependent Claim 37 words

A catalyst composition of claim 40 wherein the solid, porous carrier is silica which, prior to contact thereof with the solvent in step (i), is heated at a temperature of about 100° C. to about 1000° C.

Claim 44

Dependent Claim 18 words

A catalyst composition of claim 41 wherein the silica is heated at a temperature of about 800° C.

Claim 45

Dependent Claim 38 words

A catalyst composition of claim 42 wherein the silica has, after the heating, surface hydroxyl group concentration of about 0.5 mmoles/gr, a surface area of 300 m 2 /gram and a pore volume of 1.65 m 3 /gram.

Claim 46

Dependent Claim 34 words

A catalyst composition of claim 43 wherein the product of said step (iii), prior to conducting said step (iv), is dried at about 40° to about 65° C. to substantially remove the non-polar solvent.

Claim 47

Dependent Claim 121 words

A process of claim 1 wherein in said step (i) only such an amount of the organomagnesium composition is used which will be deposited onto the carrier; in said step (ii) only such an amount of the compound of the formula (II) is used which is sufficient to convert substantially all of the magnesium alkyl groups on the carrier to magnesium alkoxy groups, so that substantially no excess of the formula (II) compound is present in the non-polar solvent after substantially all of the magnesium groups are converted to the magnesium alkoxy groups; and in said step (iii) such an amount of the transition metal compound is used which is not greater than that which can be deposited on the carrier.

Claim 48

Dependent Claim 36 words

A process of claim 8 wherein the amount of the transition metal compound present in said step (iii) is such that the molar ratio of Mg to the transition metal is about 1 to about 3.

Claim 49

Dependent Claim 36 words

A process of claim 46 wherein the amount of the transition metal compound present in said step (iii) is such that the molar ratio of Mg to the transition metal is about 2 to about 3.

Claim 50

Dependent Claim 36 words

A process of claim 46 wherein the amount of the transition metal compound present in said step (iii) is such that the molar ratio of Mg to the transition metal is about 1.65 to about 2.40.

Claim 51

Dependent Claim 27 words

A process of claim 22 wherein the produce of said step (iii), prior to conduting said step (iv), is dried at about 45° to about 55° C.

Claim 52

Dependent Claim 24 words

A process of claim 49 wherein the product of said step (iii), prior to conducting said step (iv), is dried at about 50° C.

Claim 53

Dependent Claim 122 words

A catalyst composition of claim 23 wherein in said step (i) only such an amount of the organomagnesium composition is used which will be deposited onto the carrier; in said step (ii) only such an amount of the compound of the formula (II) is used which is sufficient to convert substantially all of the magnesium alkyl groups on the carrier to magnesium alkoxy groups, so that substantially no excess of the formula (II) compound is present in the non-polar solvent after substantially all of the magnesium groups are converted to the magnesium alkoxy groups; and in said step (iii) such an amount of the transition metal compound is used which is not greater than that which can be deposited on the carrier.

Claim 54

Dependent Claim 36 words

A catalyst of claim 30 wherein the amount of the transition metal compound present in said step (iii) is such that the molar ratio of Mg to the transition metal is about 1 to about 3.

Claim 55

Dependent Claim 36 words

A catalyst of claim 52 wherein the amount of the transition metal compound present in said step (iii) is such that the molar ratio of Mg to the transition metal is about 2 to about 3.

Claim 56

Dependent Claim 36 words

A catalyst of claim 52 wherein the amount of the transition metal compound present in said step (iii) is such that the molar ratio of Mg to the transition metal is about 1.65 to about 2.40.

Claim 57

Dependent Claim 27 words

A catalyst of claim 44 wherein the product of said step (iii), prior to conducting said step (iv), is dried at about 45° to about 55° C.

Claim 58

Dependent Claim 25 words

A catalyst composition of claim 55 wherein the product of said step (iii), prior to conducting said step (iv), is dried at about 50° C.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1992-07-17	1993-01-16	1993-07-18	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1996-07-17	1997-01-16	1997-07-18	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2000-07-17	2001-01-16	2001-07-18	$7700.00	Window Closed / Lapsed

Catalyst composition for polymerizing alpha-olefin polymers of narrow molecular weight distribution

Abstract

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