US5288677A — Immobilized Lewis acid catalysts

Claim 1

Independent Claim 187 words

Immobilized Lewis Acid catalyst comprising polymer having at least one Lewis Acid immobilized within the structure therein, said polymer having monomer units represented by the structural formula: ##STR19## wherein a represents about 1 to about 99 mole % b represents about 0 to about 50 mole % c represents about 1 to about 99 mole % a+b+c=100%; ##STR20## C is selected from the group consisting of: ##STR21## D is OH, halide, OR 4 , NH 2 , NHR 3 OM', or OM"; E is at least one Lewis Acid; R 1 represents H, C 1 -C 24 alkyl group, or C 3 -C 24 cycloalkyl; R 2 represents C 1 -C 24 alkyl group, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 3 represents C 1 -C 24 alkyl, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 4 represents C 1 -C 24 alkyl, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; M' represents alkali metal; and M" represents alkaline-earth metal.

Claim 2

Dependent Claim 187 words

Immobilized Lewis Acid catalyst comprising polymer having at least one Lewis Acid immobilized within the structure therein, said polymer having monomer units represented by the structural formula: ##STR19## wherein a represents about 1 to about 99 mole % b represents about 0 to about 50 mole % c represents about 1 to about 99 mole % a+b+c=100%; ##STR20## C is selected from the group consisting of: ##STR21## D is OH, halide, OR 4 , NH 2 , NHR 3 OM', or OM"; E is at least one Lewis Acid; R 1 represents H, C 1 -C 24 alkyl group, or C 3 -C 24 cycloalkyl; R 2 represents C 1 -C 24 alkyl group, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 3 represents C 1 -C 24 alkyl, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 4 represents C 1 -C 24 alkyl, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; M' represents alkali metal; and M" represents alkaline-earth metal.

Claim 3

Dependent Claim 25 words

The immobilized catalyst of claim 1, wherein said monomer units A, B, and C have a backbone derived from propylene, 1-butene, ethylene and mixtures thereof.

Claim 4

Dependent Claim 31 words

The immobilized catalyst of claim 1, wherein E is derived from Lewis Acid selected from the group consisting of boron halides, aluminum halides, alkyl aluminum halides, titanium halides and combinations thereof.

Claim 5

Dependent Claim 20 words

The immobilized catalyst of claim 2, wherein the backbone of monomer units A, B, and C is derived from propylene.

Claim 6

Dependent Claim 20 words

The immobilized catalyst of claim 2, wherein the backbone of monomer units A, B, and C is derived from 1-butene.

Claim 7

Dependent Claim 11 words

The immobilized catalyst of claim 1 wherein monomer unit is: ##STR22##

Claim 8

Dependent Claim 20 words

The catalyst of claim 1 wherein the carbon content of R 2 is C 3 to about C 20 alkyl.

Claim 9

Dependent Claim 13 words

The immobilized catalyst of claim 1 which is coated on a solid substrate.

Claim 10

Dependent Claim 16 words

The immobilized catalyst of claim 8 wherein the catalyst is coated on said substrate by extrusion.

Claim 11

Dependent Claim 16 words

The immobilized catalyst of claim 8 wherein the catalyst is coated on the substrate by molding.

Claim 12

Dependent Claim 17 words

The immobilized catalyst of claim 8 wherein the substrate is the inner wall of a polymerization reactor.

Claim 13

Dependent Claim 36 words

Immobilized catalyst of any one of claims 8, 9, or 10 wherein the substrate comprises at least one member of the group consisting of glass, glass fiber, metal, plastic including thermoplastic, ceramic, carbon, and mixtures thereof.

Claim 14

Independent Claim 252 words

A method of manufacturing a molded immobilized catalyst comprising a thermoplastic immobilized Lewis Acid catalyst comprising polymer having at least one Lewis Acid immobilized within the structure therein, said polymer having monomer units represented by the structural formula: ##STR23## wherein a represents about 1 to about 99 mole % b represents about 0 to about 50 mole % c represents about 1 to about 99 mole % a+b+c=100%; ##STR24## C is selected from the group consisting of: ##STR25## D is OH, halide, OR 4 NH 2 , NHR 3 , OM', or OM"; E is at least one Lewis Acid; R 1 represents H, C 1 -C 24 alkyl group, or C 3 -C 24 cycloalkyl; R 2 represents C 1 -C 24 alkyl group, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 3 represents C 1 -C 24 alkyl, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 4 represents C 1 -C 24 alkyl, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; M' represents alkali metal; and M" represents alkaline-earth metal to a sufficient temperature to produce a flowable state, transporting the heated, immobilized catalyst under sufficient pressure into a mold containing at least one cavity, filling said cavity with the immobilized catalyst, cooling the molded immobilized catalyst for a time sufficient to achieve a non-flowable state, and removing the molded catalyst from said mold.

Claim 15

Independent Claim 252 words

A method of manufacturing a molded immobilized catalyst comprising a thermoplastic immobilized Lewis Acid catalyst comprising polymer having at least one Lewis Acid immobilized within the structure therein, said polymer having monomer units represented by the structural formula: ##STR23## wherein a represents about 1 to about 99 mole % b represents about 0 to about 50 mole % c represents about 1 to about 99 mole % a+b+c=100%; ##STR24## C is selected from the group consisting of: ##STR25## D is OH, halide, OR 4 NH 2 , NHR 3 , OM', or OM"; E is at least one Lewis Acid; R 1 represents H, C 1 -C 24 alkyl group, or C 3 -C 24 cycloalkyl; R 2 represents C 1 -C 24 alkyl group, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 3 represents C 1 -C 24 alkyl, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 4 represents C 1 -C 24 alkyl, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; M' represents alkali metal; and M" represents alkaline-earth metal to a sufficient temperature to produce a flowable state, transporting the heated, immobilized catalyst under sufficient pressure into a mold containing at least one cavity, filling said cavity with the immobilized catalyst, cooling the molded immobilized catalyst for a time sufficient to achieve a non-flowable state, and removing the molded catalyst from said mold.

Claim 16

Independent Claim 217 words

A method of manufacturing immobilized Lewis Acid catalysts comprising the steps of reacting a functionalized copolymer having repeating monomer units represented by the formula: ##STR26## with a Lewis Acid under reaction conditions effective to produce an immobilized Lewis Acid catalyst comprising polymer having repeating monomer units represented by the structural formula: ##STR27## wherein a represents about 1 to about 99 mole % b represents about 0 to about 50 mole % c represents about 1 to about 99 mole % a+b+c is preferably about 100% d represents b+c ##STR28## C is selected from the group consisting of: ##STR29## D is OH, halide, OR 4 , NH 2 , NHR 3 , OM', or OM"; E at least one Lewis Acid; R 1 represents H, C 1 -C 24 alkyl group, or C 3 -C 24 cycloalkyl; R 2 represents C 1 -C 24 alkyl group, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 3 represents C 6 -C 18 alkyl, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 4 represents C 1 -C 18 alkyl, C 3 -C 24 cycloalkyl, C 1 -C 18 aryl, or C 7 -C 30 alkylaryl; M' represents alkali metal; M" represents alkaline-earth metal.

Claim 17

Independent Claim 217 words

A method of manufacturing immobilized Lewis Acid catalysts comprising the steps of reacting a functionalized copolymer having repeating monomer units represented by the formula: ##STR26## with a Lewis Acid under reaction conditions effective to produce an immobilized Lewis Acid catalyst comprising polymer having repeating monomer units represented by the structural formula: ##STR27## wherein a represents about 1 to about 99 mole % b represents about 0 to about 50 mole % c represents about 1 to about 99 mole % a+b+c is preferably about 100% d represents b+c ##STR28## C is selected from the group consisting of: ##STR29## D is OH, halide, OR 4 , NH 2 , NHR 3 , OM', or OM"; E at least one Lewis Acid; R 1 represents H, C 1 -C 24 alkyl group, or C 3 -C 24 cycloalkyl; R 2 represents C 1 -C 24 alkyl group, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 3 represents C 6 -C 18 alkyl, C 3 -C 24 cycloalkyl, C 6 -C 18 aryl, or C 7 -C 30 alkylaryl; R 4 represents C 1 -C 18 alkyl, C 3 -C 24 cycloalkyl, C 1 -C 18 aryl, or C 7 -C 30 alkylaryl; M' represents alkali metal; M" represents alkaline-earth metal.

Claim 18

Dependent Claim 24 words

The process of claim 14 wherein said repeating monomer units A, B, and C have a backbone derived from propylene, 1-butene, and mixtures thereof.

Claim 19

Dependent Claim 19 words

The process of claim 15 wherein the backbone of monomer units A, B, and C is derived from 1-butene.

Claim 20

Dependent Claim 19 words

The process of claim 15 wherein the backbone of monomer units A, B, and C is derived from propylene.

Claim 21

Dependent Claim 34 words

The process of claim 14 wherein the Lewis Acid from which substituent E is derived is selected from the group consisting of boron halides, aluminum halides, alkyl aluminum halides, titanium halides, and combinations thereof.

Claim 22

Dependent Claim 8 words

The process of claim 14 wherein is: ##STR30##

Claim 23

Dependent Claim 19 words

The process of claim 14 wherein in said immobilized catalyst R 2 is C 4 to C 20 alkyl.

Claim 24

Dependent Claim 22 words

The process of claim 14 wherein in the functionalized copolymer, is OM' or OM" and the Lewis Acid is BF 3 .

Claim 25

Dependent Claim 19 words

The immobilized catalyst of claims 1 and 14 wherein the value of "a" is at least about 50 mole%.

Claim 26

Dependent Claim 23 words

The method of manufacturing immobilized Lewis Acid catalysts of claim 14 wherein the value of a is at least about 50 mole %.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1997-02-21	1997-08-23	1998-02-22	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2001-02-21	2001-08-23	2002-02-22	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2005-02-21	2005-08-23	2006-02-22	$7700.00	Window Closed / Lapsed

Immobilized Lewis acid catalysts

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