Catalyst system for the polymerization of olefins

Claim 2

In a system for the polymerization and copolymerization of olefins, the combination comprising: (a) a solid catalyst component prepared by: (i) suspending a dialkoxy magnesium in an aromatic hydrocarbon that is liquid at normal temperatures, (ii) contacting the dialkoxy magnesium with a titanium halide and further contacting the resulting composition a second time with the titanium halide, and (iii) contacting the dialkoxy magnesium with a diester of an aromatic dicarboxylic acid at some point during the treatment with the titanium halide in (ii); and (b) an electron donor described by the formula: ##STR5## wherein R 1 is a bulky alkyl or cycloalkyl group containing at least one secondary or tertiary carbon atom; R 2 and R 3 are each independently an alkyl or aryl group; and R 4 is an alkyl group with an primary carbon atom attached to the silicon atom.

Claim 3

The combination of claim 1 wherein R 1 is a cyclohexyl group or a t-butyl group.

Claim 4

The combination of claim 1 wherein R 2 and R 3 are selected from the group consisting of methyl, ethyl, propyl, and butyl groups.

Claim 5

The combination of claim 1 wherein R 4 contains 1-6 carbon atoms.

Claim 6

The combination of claim 1 further comprising: (c) an organoaluminum compound.

Claim 7

The combination of claim 5 wherein the organoaluminum compound is selected from the group consisting of an alkylaluminum, an alkylaluminum dihalide, a trialkoxyaluminum, a dialkylaluminum halide and a triisobutylaluminum.

Claim 8

The combination of claim 5 wherein the organoaluminum compound is triethylaluminum.

Claim 9

The combination of claim 1 wherein the electron donor is methylcyclohexyldimethoxysilane.

Claim 10

The combination of claim 7 wherein the electron donor is methylcyclohexyldimethoxysilane.

Claim 11

A catalyst system for the polymerization and copolymerization of olefins, said system comprising: (a) a solid catalyst component prepared by: (i) suspending a dialkoxy magnesium in an aromatic hydrocarbon that is liquid at normal temperatures, (ii) contacting the dialkoxy magnesium with a titanium halide and further contacting the resulting composition a second time with the titanium halide, and (iii) contacting the dialkoxy magnesium with a diester of an aromatic dicarboxylic acid at some point during the treatment with the titanium halide in (ii); and (b) an electron donor described by the formula: ##STR6## wherein R 1 is a bulky alkyl or cycloalkyl group containing at least one secondary or tertiary carbon atom; R 2 and R 3 are each independently an alkyl or aryl group; and R 4 is an alkyl group with an primary carbon atom attached to the silicon atom; and (c) an organoaluminum compound; said system being characterized by: (i) a catalyst efficiency of at least about 30 kilograms of polymer product per gram of catalyst in two hours as the mole ratio Al/Si as derived from the Al in compound (c) to the Si from compound (b) is within the range of 20-200.

Claim 12

A catalyst system for the polymerization and copolymerization of olefins, said system comprising: (a) a solid catalyst component prepared by: (i) suspending a dialkoxy magnesium in an aromatic hydrocarbon that is liquid at normal temperatures, (ii) contacting the dialkoxy magnesium with a titanium halide and further contacting the resulting composition a second time with the titanium halide, and (iii) contacting the dialkoxy magnesium with a diester of an aromatic dicarboxylic acid at some point during the treatment with the titanium halide in (ii); and (b) an electron donor described by the formula: ##STR6## wherein R 1 is a bulky alkyl or cycloalkyl group containing at least one secondary or tertiary carbon atom; R 2 and R 3 are each independently an alkyl or aryl group; and R 4 is an alkyl group with an primary carbon atom attached to the silicon atom; and (c) an organoaluminum compound; said system being characterized by: (i) a catalyst efficiency of at least about 30 kilograms of polymer product per gram of catalyst in two hours as the mole ratio Al/Si as derived from the Al in compound (c) to the Si from compound (b) is within the range of 20-200.

Claim 13

The system of claim 10 wherein the system is further characterized by: (ii) an isotactic capacity such that the system produces a polymer product in which the xylene solubles are controlled within the range of 2-10 wt % of the polymer product while the Al/Si mole ratio varies up to 200.

Claim 14

The system of claim 10 wherein the system is further characterized by: (ii) an ability to accurately control the molecular weight distribution (MWD) of the polymer product within the range 4-12 while the melt flow index of the product ranges from 1-50 g/10 min.

Claim 15

The system of claim 10 wherein R 1 is selected from a cyclohexyl group or a t-butyl group.

Claim 16

The system of claim 10 wherein R 2 and R 3 are selected from the group consisting of methyl, ethyl, propyl and butyl groups.

Claim 17

The system of claim 10 wherein R 4 is a group containing 1-6 carbon atoms.

Claim 18

The system of claim 10 wherein the catalyst is prepolymerized.

Claim 19

The system of claim 10 wherein the organoaluminum compound is selected from the group consisting of an alkylaluminum, an alkylaluminum dihalide, a trialkoxyaluminum, a dialkylaluminum halide and a triisobutylaluminum.

Claim 20

The system of claim 10 wherein the electron donor is methylcyclohexyldimethoxysilane.

Claim 21

The system of claim 10 wherein the organoaluminum compound is triethylaluminum.