Preparation of supported metallocene/aluminoxane solid catalyst

Claim 1

A process for preparing a supported metallocene/aluminoxane solid catalyst which comprises the steps of: a) preparing a water-in-oil emulsion by combining a first inert solvent, water, and emulsifier, wherein the volume ratio of said first inert solvent, water, and emulsifier is about 100:0.5 to 10:0.1 to 1; b) dissolving an organoaluminum compound in a second inert solvent to make a solution having about 5 to about 30% by weight of the organoaluminum compound; c) adding dropwise said emulsion to said solution of the organoaluminum compound in a molar ratio of the organoaluminum compound to water in emulsion of about 0.8 to 2:1 in an inert atmosphere at a temperature of about -10° to about 40° C. and a rate of about 0.2 to about 20 ml/min, followed by heating the resulting solution to a temperature of about 40° to about 80° C. and allowing the reaction to proceed for about 1 to about 4 hours to obtain a suspension of a particulate aluminoxane; and d) adding a solution of a transition metal metallocene to said suspension of the particulate aluminoxane in a molar ratio of transition metal atom to aluminum atom of about 1:100 to 10,000 at about 0° to about 60° C. for about 1 to about 4 hours and removing the solvent to form said catalyst, wherein said transition metal is selected from a metal in Group IV B of the Periodic Table.