US4866021A — Catalyst composition for preparing high density, …

Claim 1

Independent Claim 141 words

An olefin polymerization catalyst precursor composition synthesized by a process comprising the steps of: (1) contacting a slurry of a solid, porous carrier with an organo metallic compound of a metal of Group IIB of the Periodic Chart of the Elements, wherein the metal is zinc, cadmium or mercury; (2) contacting the product of step (1) with an aluminum compound of the formula R.sub.n AlX(.sub.3-n) (I) where R is a C 1 -C 10 alkyl group, X is a halogen and n is 1 or 2; (3) contacting the product of step (2) with a vanadium compound of the formula ##STR1## where X' is a halogen, k is 2, 3, 4 or 5, and m is 0 or 1; and (4) contacting the product of step (3) with a titanium compound of the formula TiX".sub.4 (III) where X" is a halogen.

Claim 2

Dependent Claim 141 words

An olefin polymerization catalyst precursor composition synthesized by a process comprising the steps of: (1) contacting a slurry of a solid, porous carrier with an organo metallic compound of a metal of Group IIB of the Periodic Chart of the Elements, wherein the metal is zinc, cadmium or mercury; (2) contacting the product of step (1) with an aluminum compound of the formula R.sub.n AlX(.sub.3-n) (I) where R is a C 1 -C 10 alkyl group, X is a halogen and n is 1 or 2; (3) contacting the product of step (2) with a vanadium compound of the formula ##STR1## where X' is a halogen, k is 2, 3, 4 or 5, and m is 0 or 1; and (4) contacting the product of step (3) with a titanium compound of the formula TiX".sub.4 (III) where X" is a halogen.

Claim 3

Dependent Claim 26 words

A precursor composition of claim 1 wherein the organo-metallic compound of a metal of Group IIB used in said step 1 is a compound of zinc.

Claim 4

Dependent Claim 37 words

A precursor composition of claim 2 wherein the amount of the compounds of Formulae (I), (II) and (III) used in the synthesis process is such that the molar ratio of Al:(Ti+V) is about 0.7:1 to about 1.6:1.

Claim 5

Dependent Claim 37 words

A precursor composition of claim 3 wherein the amount of the compounds of Formulae (I), (II) and (III) used in the synthesis process is such that the molar ratio of Al:(Ti+V) is about 1:1 to about 1.4:1.

Claim 6

Dependent Claim 19 words

A precursor composition of claim 4 wherein the compound of zinc is a zinc alkyl or a zinc dialkyl.

Claim 7

Dependent Claim 32 words

A precursor composition of claim 5 wherein each of the alkyl moieties in the zinc alkyl or the zinc dialkyl is the same or a different C 1 -C 7 alkyl group.

Claim 8

Dependent Claim 13 words

A precursor composition of claim 6 wherein the compound of zinc is diethylzinc.

Claim 9

Dependent Claim 16 words

A precursor composition of claim 7 wherein R is a C 1 -C 5 alkyl group.

Claim 10

Dependent Claim 16 words

A precursor composition of claim 8 wherein R is a C 1 -C 3 alkyl group.

Claim 11

Dependent Claim 12 words

A precursor composition of claim 9 wherein R is an ethyl group.

Claim 12

Dependent Claim 12 words

A precursor composition of claim 10 wherein X is Cl or Br.

Claim 13

Dependent Claim 14 words

A precursor composition of claim 11 wherein X is Cl and n is 2.

Claim 14

Dependent Claim 12 words

A precursor composition of claim 12 wherein X' is Cl or Br.

Claim 15

Dependent Claim 17 words

A precursor composition of claim 13 wherein X' is Cl, m is 1 and k is 5.

Claim 16

Dependent Claim 10 words

A precursor composition of claim 14 wherein X" is Cl.

Claim 17

Dependent Claim 72 words

An olefin polymerization catalyst composition comprising a precursor of claim 1 combined with a co-catalyst containing at least one organo-metallic compound of elements of Groups IB, IIA, IIB, IIIB or IVB of the Periodic Chart of the Elements and a halogenating agent of the formula ##EQU3## where M is Si, C, Ge or Sn, X'" is a halogen, r is 0, 1, 2 or 3 and p is the valence of M.

Claim 18

Dependent Claim 26 words

A catalyst composition of claim 16 wherein the co-catalyst is a Group IIIB metal alkyl or dialkylhalide having 1 to 20 carbon atoms per alkyl radical.

Claim 19

Dependent Claim 22 words

A catalyst composition of claim 17 wherein the co-catalyst is a trialkylaluminum compound having 1 to 6 carbon atoms per alkyl radical.

Claim 20

Dependent Claim 11 words

A catalyst composition of claim 18 wherein the co-catalyst is triisobutylaluminum.

Claim 21

Dependent Claim 22 words

A catalyst composition of claim 19 wherein in the halogenating agent M is Si or C and X'" is Cl or Br.

Claim 22

Dependent Claim 20 words

A catalyst composition of claim 20 wherein the halogenating agent is methylene chloride, chloroform, carbon tetrachloride, dichlorosilane, trichlorosilane or silicontetrachloride.

Claim 23

Dependent Claim 12 words

A catalyst composition of claim 21 wherein the halogenating agent is chloroform.

Claim 24

Dependent Claim 23 words

A catalyst composition of claim 22 wherein the molar ratios of the co-catalyst to the halogenating agent are about 0.13:1 to about 7.5:1.

Claim 25

Dependent Claim 23 words

A catalyst composition of claim 23 wherein the molar ratios of the co-catalyst to the halogenating agent are about 0.5:1 to about 2:1.

Claim 26

Dependent Claim 20 words

A catalyst composition of claim 24 wherein the molar ratios of the co-catalyst to the halogenating agent are about 1:1.

Claim 27

Dependent Claim 73 words

An olefin polymerization catalyst composition comprising a precursor of claim 15 combined with a co-catalyst containing at least one organo-metallic compound of elements of Groups IB, IIA, IIB, IIIB or IVB of the Periodic Chart of the Elements and a halogenating agent of the formula MH.sub.r X'".sub.(p-r) where M is Si, C, Ge or Sn, X'" is a halogen, r is 0, 1, 2 or 3 and p is the valence of M.

Claim 28

Dependent Claim 26 words

A catalyst composition of claim 26 wherein the co-catalyst is a Group IIIB metal alkyl or dialkylhalide having 1 to 20 carbon atoms per alkyl radical.

Claim 29

Dependent Claim 22 words

A catalyst composition of claim 27 wherein the co-catalyst is a trialkylaluminum compound having 1 to 6 carbon atoms per alkyl radical.

Claim 30

Dependent Claim 11 words

A catalyst composition of claim 28 wherein the co-catalyst is triisobutylaluminum.

Claim 31

Dependent Claim 22 words

A catalyst composition of claim 29 wherein in the halogenating agent M is Si or C and X'" is Cl or Br.

Claim 32

Dependent Claim 20 words

A catalyst composition of claim 30 wherein the halogenating agent is methylene chloride, chloroform, carbon tetrachloride, dichlorosilane, trichlorosilane or silicontetrachloride.

Claim 33

Dependent Claim 12 words

A catalyst composition of claim 31 wherein the halogenating agent is chloroform.

Claim 34

Dependent Claim 23 words

A catalyst composition of claim 32 wherein the molar ratios of the co-catalyst to the halogenating agent are about 0.13:1 to about 7.5:1.

Claim 35

Dependent Claim 23 words

A catalyst composition of claim 33 wherein the molar ratios of the co-catalyst to the halogenating agent are about 0.5:1 to about 2:1.

Claim 36

Dependent Claim 20 words

A catalyst composition of claim 34 wherein the molar ratios of the co-catalyst to the halogenating agent are about 1:1.

Claim 37

Dependent Claim 43 words

A precursor composition of claim 1 wherein the amount of the metal or a compound of a metal of Group IIB used in said step (1) is such that it is deposited onto the carrier without leaving any excess thereof in the slurry.

Claim 38

Dependent Claim 144 words

An olefin polymerization catalyst precursor composition synthesized by a process consisting essentially of the steps of: (1) contacting a slurry of a solid, porous carrier with an organo-metallic compound of a metal of Group IIB of the Periodic Chart of the Elements, wherein the metal is zinc, cadmium or mercury; (2) contacting the product of step (1) with an aluminum compound of the formula R.sub.n AlX.sub.(3-n) (I) where R is a C 1 -C 10 alkyl group, X is a halogen and n is 1 or 2; (3) contacting the product of step (2) with a vanadium compound of the formula VO.sub.m X'.sub.(k-2m) (II) where X' is a halogen, k is 2, 3, 4 or 5, and m is 0 or 1; and (4) contacting the product of step (3) with a titanium compound of the formula TiX".sub.4 (III) where X" is a halogen.

Claim 39

Dependent Claim 144 words

An olefin polymerization catalyst precursor composition synthesized by a process consisting essentially of the steps of: (1) contacting a slurry of a solid, porous carrier with an organo-metallic compound of a metal of Group IIB of the Periodic Chart of the Elements, wherein the metal is zinc, cadmium or mercury; (2) contacting the product of step (1) with an aluminum compound of the formula R.sub.n AlX.sub.(3-n) (I) where R is a C 1 -C 10 alkyl group, X is a halogen and n is 1 or 2; (3) contacting the product of step (2) with a vanadium compound of the formula VO.sub.m X'.sub.(k-2m) (II) where X' is a halogen, k is 2, 3, 4 or 5, and m is 0 or 1; and (4) contacting the product of step (3) with a titanium compound of the formula TiX".sub.4 (III) where X" is a halogen.

Claim 40

Dependent Claim 25 words

A precursor of claim 37 wherein the organo-metallic compound of a metal of Group IIB used in said step 1 is a compound of zinc.

Claim 41

Dependent Claim 36 words

A precursor of claim 38 wherein the amount of the compounds of Formulae (I), (II) and (III) used in the synthesis process is such that the molar ratio of Al:(Ti+V) is about 0.7:1 to about 1.6:1.

Claim 42

Dependent Claim 36 words

A precursor of claim 39 wherein the amount of the compounds of Formulae (I), (II) and (III) used in the synthesis process is such that the molar ratio of Al:(Ti+V) is about 1:1 to about 1.4:1.

Claim 43

Dependent Claim 18 words

A precursor of claim 40 wherein the compound of zinc is a zinc alkyl or a zinc dialkyl.

Claim 44

Dependent Claim 31 words

A precursor of claim 41 wherein each of the alkyl moieties in the zinc alkyl or the zinc dialkyl is the same or a different C 1 -C 7 alkyl group.

Claim 45

Dependent Claim 12 words

A precursor of claim 42 wherein the compound of zinc is diethylzinc.

Claim 46

Dependent Claim 15 words

A precursor of claim 43 wherein R is a C 1 -C 5 alkyl group.

Claim 47

Dependent Claim 15 words

A precursor of claim 44 wherein R is a C 1 -C 3 alkyl group.

Claim 48

Dependent Claim 11 words

A precursor of claim 45 wherein R is an ethyl group.

Claim 49

Dependent Claim 11 words

A precursor of claim 46 wherein X is Cl or Br.

Claim 50

Dependent Claim 13 words

A precursor of claim 47 wherein X is Cl and n is 2.

Claim 51

Dependent Claim 11 words

A precursor of claim 48 wherein X' is Cl or Br.

Claim 52

Dependent Claim 16 words

A precursor of claim 47 wherein X' is Cl, m is 1 and k is 5.

Claim 53

Dependent Claim 9 words

A precursor of claim 50 wherein X" is Cl.

Claim 54

Dependent Claim 72 words

An olefin polymerization catalystcomposition containing a precursor of claim 37 combined with a co-catalyst containing at least one organo-metallic compound of elements of Groups IB, IIA, IIB, IIIB or IVB of the Periodic Chart of the Elements and a halogenating agent of the formula MH.sub.r X'".sub.(p-r) where M is Si, C, Ge or Sn, X'" is a halogen, r is 0, 1, 2 or 3 and p is the valence of M.

Claim 55

Dependent Claim 25 words

A catalyst of claim 52 wherein the co-catalyst is a Group IIIB metal alkyl or dialkylhalide having 1 to 20 carbon atoms per alkyl radical.

Claim 56

Dependent Claim 21 words

A catalyst of claim 53 wherein in the halogenating agent M is Si or C and X'" is Cl or Br.

Claim 57

Dependent Claim 21 words

A catalyst of claim 54 wherein the co-catalyst is a trialkylaluminum compound having 1 to 6 carbon atoms per alkyl radical.

Claim 58

Dependent Claim 10 words

A catalyst of claim 55 wherein the co-catalyst is triisobutylaluminum.

Claim 59

Dependent Claim 19 words

A catalyst of claim 56 wherein the halogenating agent is methylene chloride, chloroform, carbon tetrachloride, dichlorosilane, trichlorosilane or silicontetrachloride.

Claim 60

Dependent Claim 11 words

A catalyst of claim 57 wherein the halogenating agent is chloroform.

Claim 61

Dependent Claim 22 words

A catalyst of claim 58 wherein the molar ratios of the co-catalyst to the halogenating agent are about 0.13:1 to about 7.5:1.

Claim 62

Dependent Claim 22 words

A catalyst of claim 59 wherein the molar ratios of the co-catalyst to the halogenating agent are about 0.5:1 to about 2:1.

Claim 63

Dependent Claim 19 words

A catalyst of claim 60 wherein the molar ratios of the co-catalyst to the halogenating agent are about 1:1.

Claim 64

Dependent Claim 73 words

An olefin polymerization catalyst composition containing a precursor of claim 51 combined with a co-catalyst containing at least one organo-metallic compound of elements of Groups IB, IIA, IIB, IIIB or IVB of the Periodic Chart of the Elements and a halogenating agent of the formula MH.sub.r X'".sub.(p-r) where M is Si, C, Ge r Sn, X'" is a halogen, r is 0, 1, 2 or 3, and p is the valence of M.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1992-09-11	1993-03-13	1993-09-12	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1996-09-11	1997-03-13	1997-09-12	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2000-09-11	2001-03-13	2001-09-12	$7700.00	Window Closed / Lapsed

Catalyst composition for preparing high density, broad molecular weight distribution alpha-olefin polymers

Abstract

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