Method for producing α-olefin polymers

Claim 2

In a process for preparing α-olefin polymers in which an α-olefin is contacted with a catalyst to polymerize, the improvement which comprise the use as the catalyst of a solid product comprising Components (ii) and (iii) supported on Component (i): Component (i) being an organic porous polymer having an average particle diameter of 5 to 1,000 μm, in which the total pore volume of all pores whose diameter is 0.006 to 10 μm is no smaller than 0.3 cc/g, and the total pore volume of all pores whose diameter is 0.05 to 2 μm is no smaller than 50% of the total pore volume of all pores whose diameter is 0.006 to 10 μm; Component (ii) being a compound having the structure ##STR6## in which R is a hydrocarbyl group having 1 to 10 carbon atoms; and Component (iii) being a compound of a transition metal of the Groups IVB to VIB in the Periodic Table, having at least one conjugated 5-membered cyclic ligand.

Claim 3

A method for preparing an α-olefin polymer as set forth in claim 1, wherein the organic porous polymer, Component (i), is one having an average particle diameter of 10 to 700 μm.

Claim 4

A method for preparing an α-olefin polymer as set forth in claim 1, wherein the organic porous polymer, the component (i), is one having an average particle diameter of 20 to 500 μm.

Claim 5

A method for preparing an α-olefin polymer as set forth in claim 1, wherein the organic porous polymer, Component (i), is one having a total pore volume of all pores whose diameter is 0.006 to 10 μm of no smaller than 0.8 cc/g.

Claim 6

A method for preparing an α-olefin polymer as set forth in claim 1, wherein the organic porous polymer, Component (i), is one having a total pore volume of all pores whose diameter is 0.006 to 10 μm of no smaller than 1.0 cc/g.

Claim 7

A method for preparing an α-olefin polymer as set forth in claim 1, wherein the organic porous polymer, Component (i), is one in which a total pore volume of all pores whose diameter is 0.005 to 2 μm is no smaller than 60% of a total pore volume of all pores whose diameter is 0.006 to 10 μm.

Claim 8

A method for preparing an α-olefin polymer as set forth in claim 1, wherein the organic porous polymer, Component (i), is selected from the group consisting of polymers of an α-olefin having 2 to 10 carbon atoms, polymers of styrene or its derivative having a hydrocarbyl group at its nucleus and/or side chain, and polar polymers containing an O, N or halogen atom.

Claim 9

A method for preparing an α-olefin polymer as set forth in claim 1, wherein the organic porous polymer, Component (i), is a polymer of an α-olefin having 2 to 10 carbon atoms.

Claim 10

A method for preparing an α-olefin polymer as set forth in claim 1, wherein the organic porous polymer, the component (i), is a polymer of an α-olefin which is the same one as to be finally polymerized.

Claim 11

A method for preparing an α-olefin polymer as set forth in claim 1, wherein Component (ii) is an alumoxane.

Claim 12

A method for preparing an α-olefin polymer as set forth in claim 1, wherein Component (iii) is a transition metal compound represented by the following formula (1) or (2): Q.sub.a (C.sub.5 H.sub.5-a-b R.sup.1.sub.b)(C.sub.5 H.sub.5-a-c R.sup.2.sub.c)MeXY (1) S.sub.a (C.sub.5 H.sub.5-a-d R.sup.3.sub.d)ZMeXY (2) wherein Q represents a binding group which crosslinks the two conjugated 5-membered cyclic ligands, S represents a binding group which crosslinks the conjugated 5-membered cyclic ligand and the group Z, a is 0 or 1, b, c and d are an integer which fulfills the conditions of 0≦b ≦5, 0≦c≦5 and 0≦d≦5 when a is 0, and 0≦b≦4, 0≦c≦4 and 0≦d≦4 when a is 1, R 1 , R 2 and R 3 are each a halogen atom, an alkoxy group having 1 to 12 carbon atoms, a silicon-containing hydrocarbon group having 1 to 24 carbon atoms, containing a silicon atom in the form of --Si(R)(R')(R"), a phosphorus-containing hydrocarbon group having 1 to 18 carbon atoms, containing a phosphorus atom in the form of --P(R)(R'), a nitrogen-containing hydrocarbon group having 1 to 18 carbon atoms, containing a nitrogen atom in the form of --N(R)(R'), or a boron-containing hydrocarbon group having 1 to 18 carbon atoms, containing a boron atom in the form of --B(R)(R'), provided that when b, c or d is 2 or more and a plurality of R 1 s, R 2 s or R3s are existing, they may be the same or different, Me is a transition metal of the Group of IVB to VIB in the Periodic Table, Z is oxygen (--O--), sulfur (--S--), an alkoxy group having 1 to 20 carbon atoms, a thioalkoxy group having 1 to 20 carbon atoms, a silicon-containing hydrocarbon group having 1 to 40 carbon atoms, a nitrogen-containing hydrocarbon group having 1 to 40 carbon atoms, or a phosphorus-containing hydrocarbon group having 1 to 40 carbon atoms, provided that one of the bonds in the group Z is bound to the group S, a binding group, when a is 1, and X and Y, which may be the same or different, are each hydrogen, a halogen group, a hydrocarbyl group having 1 to 20 carbon atoms, an alkoxy group having 1 to 20 carbon atoms, an amino group, a phosphorus-containing hydrocarbon group having 1 to 20 carbon atoms, or a silicon-containing hydrocarbon group having 1 to 20 carbon atoms.

Claim 13

A method for preparing an α-olefin polymer as set forth in claim 1, wherein Component (iii) is a compound of a metal, Me, selected from the group consisting of titanium, zirconium and hafnium.

Claim 14

A method for preparing an α-olefin polymer as set forth in claim 11, wherein Component (iii) is a compound wherein the a is 1 (unity) and Q or S is selected from the group consisting of an alkylene group and an alkylsilylene group.

Claim 15

A method for preparing an α-olefin polymer as set forth in claim 1, wherein the catalyst is a solid prepared by making Components (ii) and (iii) be supported in Component (i), and then subjecting the resultant to preliminary polymerization in which it is brought into contact with an olefin under the gas phase condition to give 0.01 to 500 g of a polymer of the olefin per 1 g of the total amount of Components (i), (ii) and (iii).

Claim 16

A method for preparing an α-olefin polymer as set forth in claim 14, wherein the amount of the α-olefin polymer obtained by the preliminary polymerization is 0.1 to 100 g per 1 g of the total amount of Components (i), (ii) and (iii).

Claim 17

A method for preparing an α-olefin polymer as set forth in claim 14, wherein the amount of the α-olefin polymer obtained by the preliminary polymerization is 0.2 to 30 g per 1 g of the total amount of Components (i), (ii) and (iii).

Claim 18

A method for preparing an α-olefin polymer as set forth in claim 14, wherein the α-olefin used for the preliminary polymerization is selected from the group consisting of ethylene, propylene, butene-1, 3-methylbutene-1, and a mixture thereof.

Claim 19

A method for preparing an α-olefin polymer as set forth in claim 1, wherein the catalyst is a combination of a solid which is obtained by making Components (ii) and (iii) be supported on Component (i), and an organoaluminium compound.

Claim 20

A method for preparing an α-olefin polymer as set forth in claim 14, wherein the catalyst is a combination of a solid which is obtained by making Components (ii) and (iii) be supported on Component (i), and then subjecting the resultant to preliminary polymerization in which it is brought into contact with an olefin under the gas phase condition, and an organoaluminium compound.

Claim 21

A method for preparing an α-olefin polymer as set forth in claim 1, wherein the polymerization is characterized in that a first step polymerization is conducted in the presence of the catalyst substantially under a gas phase to give a crystalline propylene homopolymer, or a propylene-ethylene copolymer having the ethylene content of 5% by weight or less, and that a second step polymerization is conducted in the presence of both the catalyst and the polymer obtained by the first step polymerization to polymerize propylene and at least one comonomer selected from the group consisting of ethylene and α-olefins having 4 to 20 carbon atoms in such a polymerization ratio in molar ratio of 0/100 to 80/20, provided that the weight ratio of the polymerization amount at the first step polymerization to the polymerization amount at the second step polymerization is 95/5 to 30/70.

Claim 22

A method for preparing an α-olefin copolymer as set forth in claim 1, wherein the polymerization is characterized in that at least two monomers selected from the group consisting of ethylene, propylene and an α-olefin of 4-20 carbon atoms are polymerized so that the two monomers are polymerized in a molar ratio of 10/90 to 90/10.