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Multimodal polymer compositions prepared using multinuclear metallocene catalysts

Assignee: SRI International Inc
•
Filing: 1999-08-11
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Granted: 2000-06-06
•
Expires: 2019-08-11
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Abstract

Abstract A process is provided for preparing polymer compositions which are multimodal in nature. The process involves contacting, under polymerization conditions, a selected addition polymerizable monomer with a metallocene catalyst having two or more distinct and chemically different active sites, and a catalyst activator.

Inventors

  • 👤 Robert B. Wilson, Jr.

Bibliographic Details

Application Number —
Jurisdiction US
Data Source google_patents
Last Synchronized 2026-10-28 11:59
CPC Classifications
C; C08; C08F; C08F12/00; C08F12/02; C08F12/04; C08F12/06; C08F12/08; C08F10/00; C08F10/02; C08F12/12; C08F14/00; C08F14/02; C08F14/04; C08F14/06; C08F14/08; C08F14/18; C08F14/20; C08F20/00; C08F20/02; C08F20/10; C08F20/12; C08F20/14; C08F20/16; C08F20/18; C08F20/42; C08F20/44; C08F36/00; C08F36/02; C08F36/04; C08F4/00; C08F4/42; C08F4/44; C08F4/60; C08F4/62; C08F4/64; C08F4/659; C08F4/6592; C08F4/65922; C08F4/65927; C08F110/00; C08F110/02; C08F2410/00; C08F2410/03; C08F2420/00; C08F2420/02; C08F4/65912; C08F4/65916; C08L; C08L23/00; C08L23/02; C08L23/04; C08L23/08; C08L23/0807; C08L23/0815; C08L2314/00; C08L2314/06; Y; Y10; Y10S; Y10S526/00; Y10S526/943

Claims Analysis

Total Claims: 38
Claim 1
Independent Claim 581 words
A polymer composition having a multimodal molecular weight composition, prepared by the process comprising contacting, under polymerization conditions, (a) an addition polymerizable monomer containing at least one degree of unsaturation, with (b) a metallocene catalyst having two or more distinct and chemically different active sites, and (c) a catalyst activator, wherein the metallocene catalyst has the structure B(Z) q of structural formula (I) ##STR32## wherein: B is a covalent bridging group comprising carbyl, silyl, disilyl, germanyl, ammonium, phosphonium, ##STR33## or a C 1 -C 24 hydrocarbyl radical optionally containing a Group IVB element, a Group VB element, or both a Group IVB element and a Group VB element, and is capable of binding up to n max substituents through single covalent bonds, where n max is at least 4; R and R 1 are independently selected from the group consisting of halogen, C 1 -C 24 hydrocarbyl, C 1 -C 24 hydrocarbyl substituted with one or more halogen atoms, and C 1 -C 24 hydrocarbyl-substituted Group IVB elements, x is 0, 1, 2, 3 or 4, and y is 0, 1, 2, 3 or 4, with the proviso that the sum of x and y cannot exceed 4, or, when R and R 1 are ortho to each other and x and y are each 1 or greater, R and R 1 can together form a five- or six-membered cyclic structure optionally substituted with one to four substituents selected from the group consisting of halogen, C 1 -C 24 hydrocarbyl, C 1 -C 24 hydrocarbyl substituted with one or more halogen atoms, and C 1 -C 24 hydrocarbyl-substituted Group IVB elements; Q is J(R 2 ) z-2 wherein J is an element with a coordination number of three from Group VB or an element with a coordination number of two from Group VIB, R 2 is selected from the group consisting of hydrogen, C 1 -C 24 hydrocarbyl, C 1 -C 24 hydrocarbyl substituted with one or more halogen atoms, and C 1 -C 24 alkoxy, and z is the coordination number of J, and further wherein Q substituents on different Z groups may be linked through a C 1 -C 24 hydrocarbylene bridge; M is a Group IIIA element, a Group IVA element, a Group VA element, a lanthanide, or an actinide; X is selected from the group consisting of hydride, halide, alkoxy, amido, C 1 -C 24 hydrocarbyl, C 1 -C 24 hydrocarbyl radicals substituted with one or more electron-withdrawing groups, and C 1 -C 24 hydrocarbyl-substituted Group IVB elements, or, when two or more X substituents are present, they may together form an alkylidene olefin, acetylene, or a five- or six-membered cyclic hydrocarbyl group; Y is a neutral Lewis base; m is 1, 2, 3 or 4, and n is 0, 1, 2 or 3, with the proviso that if M is a Group IIIA element, m is 1 and n is 0, and with the further proviso that if M is a Group IVA element, the sum of m and n does not exceed 2; if n max is 4 or 5, then q is 2, and if n max is greater than 5, then q is an integer in the range of 2 to q max , wherein q max is equal to 1/2n max when n max is an even number, and 1/2(n max -1) when n max is an odd number; and at least two of the Z substituents bound to B are different.
Claim 2
Dependent Claim 581 words
A polymer composition having a multimodal molecular weight composition, prepared by the process comprising contacting, under polymerization conditions, (a) an addition polymerizable monomer containing at least one degree of unsaturation, with (b) a metallocene catalyst having two or more distinct and chemically different active sites, and (c) a catalyst activator, wherein the metallocene catalyst has the structure B(Z) q of structural formula (I) ##STR32## wherein: B is a covalent bridging group comprising carbyl, silyl, disilyl, germanyl, ammonium, phosphonium, ##STR33## or a C 1 -C 24 hydrocarbyl radical optionally containing a Group IVB element, a Group VB element, or both a Group IVB element and a Group VB element, and is capable of binding up to n max substituents through single covalent bonds, where n max is at least 4; R and R 1 are independently selected from the group consisting of halogen, C 1 -C 24 hydrocarbyl, C 1 -C 24 hydrocarbyl substituted with one or more halogen atoms, and C 1 -C 24 hydrocarbyl-substituted Group IVB elements, x is 0, 1, 2, 3 or 4, and y is 0, 1, 2, 3 or 4, with the proviso that the sum of x and y cannot exceed 4, or, when R and R 1 are ortho to each other and x and y are each 1 or greater, R and R 1 can together form a five- or six-membered cyclic structure optionally substituted with one to four substituents selected from the group consisting of halogen, C 1 -C 24 hydrocarbyl, C 1 -C 24 hydrocarbyl substituted with one or more halogen atoms, and C 1 -C 24 hydrocarbyl-substituted Group IVB elements; Q is J(R 2 ) z-2 wherein J is an element with a coordination number of three from Group VB or an element with a coordination number of two from Group VIB, R 2 is selected from the group consisting of hydrogen, C 1 -C 24 hydrocarbyl, C 1 -C 24 hydrocarbyl substituted with one or more halogen atoms, and C 1 -C 24 alkoxy, and z is the coordination number of J, and further wherein Q substituents on different Z groups may be linked through a C 1 -C 24 hydrocarbylene bridge; M is a Group IIIA element, a Group IVA element, a Group VA element, a lanthanide, or an actinide; X is selected from the group consisting of hydride, halide, alkoxy, amido, C 1 -C 24 hydrocarbyl, C 1 -C 24 hydrocarbyl radicals substituted with one or more electron-withdrawing groups, and C 1 -C 24 hydrocarbyl-substituted Group IVB elements, or, when two or more X substituents are present, they may together form an alkylidene olefin, acetylene, or a five- or six-membered cyclic hydrocarbyl group; Y is a neutral Lewis base; m is 1, 2, 3 or 4, and n is 0, 1, 2 or 3, with the proviso that if M is a Group IIIA element, m is 1 and n is 0, and with the further proviso that if M is a Group IVA element, the sum of m and n does not exceed 2; if n max is 4 or 5, then q is 2, and if n max is greater than 5, then q is an integer in the range of 2 to q max , wherein q max is equal to 1/2n max when n max is an even number, and 1/2(n max -1) when n max is an odd number; and at least two of the Z substituents bound to B are different.
Claim 3
Dependent Claim 24 words
The polymer composition of claim 1, wherein a single addition polymerizable monomer is employed in step (a), and the polymer composition comprises a homopolymer.
Claim 4
Dependent Claim 26 words
The polymer composition of claim 1, wherein two or more different addition polymerizable monomers are employed in step (a), and the polymer composition comprises a copolymer.
Claim 5
Dependent Claim 26 words
The polymer composition of claim 1, wherein the addition polymerizable monomer of step (a) is an α-olefin having from about 2 to about 20 carbon atoms.
Claim 6
Dependent Claim 15 words
The polymer composition of claim 4, wherein the α-olefin is a linear or branched olefin.
Claim 7
Dependent Claim 37 words
The polymer composition of claim 5, wherein the α-olefin is selected from the group consisting of ethylene, propylene, 1-butene, 3-methyl-1-butene, 1,3-butadiene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 4-methyl-1-hexene, 1,4-hexadiene, 1,5-hexadiene, 1-octene, 1,6-octadiene, 1-nonene, 1-decene, 1,4-dodecadiene, 1-hexadecene, 1-octadecene, and mixtures thereof.
Claim 8
Dependent Claim 15 words
The polymer composition of claim 4, wherein the α-olefin is a cyclic olefin or diolefin.
Claim 9
Dependent Claim 26 words
The polymer composition of claim 7, wherein the α-olefin is selected from the group consisting of cyclopentene, 3-vinylcyclohexene, norbornene, 5-vinyl-2-norbornene, 5-ethylidene-2-norbornene, dicyclopentadiene, 4-vinylbenzocyclobutane, tetracyclododecene, dimethano-octahydronaphthalene, 7-octenyl-9-borabicyclo-(3,3,1)nonane.
Claim 10
Dependent Claim 18 words
The polymer composition of claim 1, wherein the addition polymerizable monomer of step (a) is an aromatic monomer.
Claim 11
Dependent Claim 36 words
The polymer composition of claim 9, wherein the aromatic monomer is selected from the group consisting of styrene, o-methylstyrene, m-methylstyrene, p-methylstyrene, p-tert-butylstyrene, m-chlorostyrene, p-chlorostyrene, p-fluorostyrene, indene, 4-vinylbiphenyl, acenaphthalene, vinylfluorene, vinylanthracene, vinylphenanthrene, vinylpyrene, vinylchrisene and mixtures thereof.
Claim 12
Dependent Claim 48 words
The polymer composition of claim 1, wherein the addition polymerizable monomer of step (a) is selected from the group consisting of methylmethacrylate, ethylacrylate, vinyl silane, phenyl silane, trimethylallyl silane, acrylonitrile, maleimide, vinyl chloride, vinylidene chloride, tetrafluoroethylene, isobutylene, carbon monoxide, acrylic acid, 2-ethylhexylacrylate, methacrylonitrile, methacrylic acid, and mixtures thereof.
Claim 13
Dependent Claim 12 words
The polymer composition of claim 1, wherein the metallocene catalyst is unsupported.
Claim 14
Dependent Claim 11 words
The polymer composition of 1, wherein the metallocene catalyst is supported.
Claim 15
Dependent Claim 11 words
The polymer composition of 1, wherein the metallocene catalyst is supported.
Claim 16
Dependent Claim 15 words
The polymer composition of claim 1, wherein the process is conducted in the liquid phase.
Claim 17
Dependent Claim 15 words
The polymer composition of claim 1, wherein the process is conducted in the gas phase.
Claim 18
Dependent Claim 14 words
The polymer composition of claim 1, wherein the process is conducted in a slurry.
Claim 19
Dependent Claim 13 words
The polymer composition of claim 1, wherein, in Formula (I), q is 2.
Claim 20
Dependent Claim 13 words
The polymer composition of claim 1, wherein, in Formula (I), q is 3.
Claim 21
Dependent Claim 201 words
The polymer composition of claim 1, wherein, in Formula (I): B is a covalent bridging group comprising carbyl, silyl, disilyl or a C 1 -C 12 hydrocarbyl radical optionally containing a Group IVB element, a Group VB element, or both; x is 0, 1 or 2; y is 0, 1 or 2; R and R 1 are independently selected from the group consisting of halogen and C 1 -C 12 alkyl, or are ortho to each other and linked to form a cyclopentadienyl or indenyl group; J is nitrogen, phosphorus, oxygen or sulfur, and R 2 is C 1 -C 12 alkyl, C 1 -C 12 alkyl substituted with a halogen atom, or monocyclic aryl; M is a Group IVA element; m is 1 or 2, n is 0 or 1, and the sum of m and n is 2; X is selected from the group consisting of hydride, halide, amido, C 1 -C 12 alkyl, C 1 -C 12 alkyl substituted with one or more halogen and/or alkoxy groups, and C 1 -C 12 hydrocarbyl-substituted Group IVB elements; Y is a selected from the group consisting of diethylether, tetrahydrofuran, dimethylaniline, aniline, trimethylphosphine, and n-butylamine; and q is 2 or 3.
Claim 22
Dependent Claim 107 words
The polymer composition of claim 19, wherein, in Formula (I): B is carbyl, a C 1 -C 6 hydrocarbyl radical or silyl; x and y are independently 0 or 1; R and R 1 are independently selected from the group consisting of halogen and lower alkyl, or are ortho to each other and linked to form a cyclopentadienyl ring; J is nitrogen, R 2 is lower alkyl or phenyl, and z is 3; M is Zr, Hf or Ti; m is 2; n is 0; X is selected from the group consisting of hydride, amido, and lower alkyl; Y is diethylether or tetrahydrofuran; and q is 2.
Claim 23
Dependent Claim 20 words
The polymer composition of claim 20, wherein, in Formula (I), the Z substituents bound to B contain different M moieties.
Claim 24
Dependent Claim 177 words
A polymer composition having a multimodal molecular weight composition, prepared by the process comprising contacting, under polymerization conditions, (a) an addition polymerizable monomer containing at least one degree of unsaturation, with (b) a metallocene catalyst having two or more distinct and chemically different active sites, and (c) a catalyst activator, wherein the metallocene catalyst has the structure ##STR34## wherein: B is carbyl, lower alkylene, lower alkenylene or silyl; Ar 1 and Ar 2 are independently selected from the group consisting of cyclopentadienyl, indenyl and fluorenyl, optionally substituted with at least one substituent selected from the group consisting of halogen and lower alkyl; M 1 and M 2 are independently selected from the group consisting of Zr, Hf and Ti; the X 1 and X 2 may be the same of different and are selected from the group consisting of halide, lower alkyl and lower alkoxy; and R 2a and R 2b are selected from the group consisting of C 1 to C 12 alkyl and phenyl, with the proviso that R 2a and R 2b are different.
Claim 25
Dependent Claim 177 words
A polymer composition having a multimodal molecular weight composition, prepared by the process comprising contacting, under polymerization conditions, (a) an addition polymerizable monomer containing at least one degree of unsaturation, with (b) a metallocene catalyst having two or more distinct and chemically different active sites, and (c) a catalyst activator, wherein the metallocene catalyst has the structure ##STR34## wherein: B is carbyl, lower alkylene, lower alkenylene or silyl; Ar 1 and Ar 2 are independently selected from the group consisting of cyclopentadienyl, indenyl and fluorenyl, optionally substituted with at least one substituent selected from the group consisting of halogen and lower alkyl; M 1 and M 2 are independently selected from the group consisting of Zr, Hf and Ti; the X 1 and X 2 may be the same of different and are selected from the group consisting of halide, lower alkyl and lower alkoxy; and R 2a and R 2b are selected from the group consisting of C 1 to C 12 alkyl and phenyl, with the proviso that R 2a and R 2b are different.
Claim 26
Dependent Claim 16 words
The polymer composition of claim 22, wherein B is selected from the group consisting of ##STR35##
Claim 27
Dependent Claim 14 words
The polymer composition of claim 22, wherein M 1 and M 2 are different.
Claim 28
Dependent Claim 15 words
The polymer composition of claim 22, wherein M 1 and M 2 are the same.
Claim 29
Dependent Claim 272 words
A polymer composition having a multimodal molecular weight composition, prepared by the process comprising contacting, under polymerization conditions, (a) an addition polymerizable monomer containing at least one degree of unsaturation, with (b) a metallocene catalyst having two or more distinct and chemically different active sites, and (c) a catalyst activator, wherein the metallocene catalyst has the structure wherein: B is carbyl, lower alkylene, lower alkenylene or silyl; Ar 1 and Ar 2 are independently selected from the group consisting of cyclopentadienyl, indenyl and fluorenyl, optionally substituted with at least one substituent selected from the group consisting of halogen and lower alkyl; M 1 and M 2 are independently selected from the group consisting of Zr, Hf and Ti; the X 1 and X 2 may be the same of different and are selected from the group consisting of halide, lower alkyl and lower alkoxy; and Q 1 and Q 2 are selected from the group consisting of cyclopentadienyl, indenyl, fluorenyl, indolyl and aminoboratobenzyl, optionally substituted with at least one substituent selected from the group consisting of halogen and lower alkyl, with the proviso that Q 1 and Q 2 are different, and with the further provisos that (a) when M 1 (X 1 ) 2 is the same as M 2 (X 2 ) 2 and Q 1 is the same as Ar 2 , then Q 2 and Ar 1 must be different, and (b) when M 1 (X 1 ) 2 is the same as M 2 (X 2 ) 2 and Q 2 is the same as Ar 1 , then Q 1 and Ar 2 must be different.
Claim 30
Dependent Claim 272 words
A polymer composition having a multimodal molecular weight composition, prepared by the process comprising contacting, under polymerization conditions, (a) an addition polymerizable monomer containing at least one degree of unsaturation, with (b) a metallocene catalyst having two or more distinct and chemically different active sites, and (c) a catalyst activator, wherein the metallocene catalyst has the structure wherein: B is carbyl, lower alkylene, lower alkenylene or silyl; Ar 1 and Ar 2 are independently selected from the group consisting of cyclopentadienyl, indenyl and fluorenyl, optionally substituted with at least one substituent selected from the group consisting of halogen and lower alkyl; M 1 and M 2 are independently selected from the group consisting of Zr, Hf and Ti; the X 1 and X 2 may be the same of different and are selected from the group consisting of halide, lower alkyl and lower alkoxy; and Q 1 and Q 2 are selected from the group consisting of cyclopentadienyl, indenyl, fluorenyl, indolyl and aminoboratobenzyl, optionally substituted with at least one substituent selected from the group consisting of halogen and lower alkyl, with the proviso that Q 1 and Q 2 are different, and with the further provisos that (a) when M 1 (X 1 ) 2 is the same as M 2 (X 2 ) 2 and Q 1 is the same as Ar 2 , then Q 2 and Ar 1 must be different, and (b) when M 1 (X 1 ) 2 is the same as M 2 (X 2 ) 2 and Q 2 is the same as Ar 1 , then Q 1 and Ar 2 must be different.
Claim 31
Dependent Claim 16 words
The polymer composition of claim 26, wherein B is selected from the group consisting of ##STR36##
Claim 32
Dependent Claim 14 words
The polymer composition of claim 26, wherein M 1 and M 2 are different.
Claim 33
Dependent Claim 15 words
The polymer composition of claim 26, wherein M 1 and M 2 are the same.
Claim 34
Dependent Claim 193 words
A polymer composition having a multimodal molecular weight composition, prepared by the process comprising contacting, under polymerization conditions, (a) an addition polymerizable monomer containing at least one degree of unsaturation, with (b) a metallocene catalyst having two or more distinct and chemically different active sites, and (c) a catalyst activator, wherein the metallocene catalyst has the structure wherein: B is carbyl, lower alkylene, lower alkenylene or silyl; Ar 1 and Ar 2 are independently selected from the group consisting of cyclopentadienyl, indenyl and fluorenyl, optionally substituted with at least one substituent selected from the group consisting of halogen and lower alkyl; M 1 and M 2 are independently selected from the group consisting of Zr, Hf and Ti; the X 1 and X 2 may be the same of different and are selected from the group consisting of halide, lower alkyl and lower alkoxy; R 2a and R 2b are independently selected from the group consisting of methylene, phenylmethylene, lower alkyl-substituted methylene, di(lower alkyl)-substituted methylene, and methylene substituted with one lower alkyl group and phenyl; L is methylene optionally substituted with 1 or 2 lower alkyl groups; and q is 0 or 1.
Claim 35
Dependent Claim 193 words
A polymer composition having a multimodal molecular weight composition, prepared by the process comprising contacting, under polymerization conditions, (a) an addition polymerizable monomer containing at least one degree of unsaturation, with (b) a metallocene catalyst having two or more distinct and chemically different active sites, and (c) a catalyst activator, wherein the metallocene catalyst has the structure wherein: B is carbyl, lower alkylene, lower alkenylene or silyl; Ar 1 and Ar 2 are independently selected from the group consisting of cyclopentadienyl, indenyl and fluorenyl, optionally substituted with at least one substituent selected from the group consisting of halogen and lower alkyl; M 1 and M 2 are independently selected from the group consisting of Zr, Hf and Ti; the X 1 and X 2 may be the same of different and are selected from the group consisting of halide, lower alkyl and lower alkoxy; R 2a and R 2b are independently selected from the group consisting of methylene, phenylmethylene, lower alkyl-substituted methylene, di(lower alkyl)-substituted methylene, and methylene substituted with one lower alkyl group and phenyl; L is methylene optionally substituted with 1 or 2 lower alkyl groups; and q is 0 or 1.
Claim 36
Dependent Claim 16 words
The polymer composition of claim 30, wherein B is selected from the group consisting of ##STR37##
Claim 37
Dependent Claim 14 words
The polymer composition of claim 31, wherein M 1 and M 2 are different.
Claim 38
Dependent Claim 15 words
The polymer composition of claim 31, wherein M 1 and M 2 are the same.

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