Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Polymers from only ethylenic monomers or processes of...
Reexamination Certificate
2001-02-02
2003-05-20
Choi, Ling-Siu (Department: 1713)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Polymers from only ethylenic monomers or processes of...
C526S348000, C526S124300, C526S123100, C526S158000, C526S142000, C526S143000, C526S119000, C526S128000, C502S110000, C502S103000, C502S126000, C502S127000, C502S115000, C502S116000
Reexamination Certificate
active
06566464
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a process for producing a solid catalyst component for &agr;-olefin polymerization, a process for producing a catalyst for &agr;-olefin polymerization, and a process for producing an &agr;-olefin polymer.
BACKGROUND OF THE INVENTION
As a catalyst for a high stereospecificity polymerization of an &agr;-olefin, the following catalysts are known.
(1) A catalyst obtained by combining a support type solid catalyst component prepared by supporting a tetravalent titanium halide on a magnesium halide with an organoaluminum compound as a co-catalyst and an organosilicon compound as a third component (refer to JP-A 57-63310, JP-A 58-83006 and JP-A 61-78803).
(2) A catalyst obtained by combining a trivalent titanium compound-containing solid catalyst component with an organoaluminum compound as a co-catalyst and an electron donor compound as a third component, wherein the trivalent titanium compound-containing solid catalyst component is prepared by reducing a titanium compound with an organomagnesium compound in the presence of both an organosilicon compound and an ester compound to obtain a solid product, and treating the solid product with an ester compound, followed by successive treatment with a mixture of an ether compound and titanium tetrachloride or a mixture of an ether compound, titanium tetrachloride and an ester compound (refer to JP-A 7-216017).
(3) A catalyst obtained by combining a trivalent titanium compound-containing solid catalyst component with an organoaluminum compound as a co-catalyst and an electron donor compound as a third component, wherein the trivalent titanium compound-containing solid catalyst component is prepared by reducing a titanium compound with an organomagnesium compound in the presence of both an organosilicon compound and an ester compound to obtain a solid product, and treating the solid product with a mixture of an ether compound and titanium tetrachloride, followed by successive treatment with an organic acid halide compound, and further followed by successive treatment with a mixture of an ether compound and titanium tetrachloride or a mixture of an ether compound, titanium tetrachloride and an ester compound (refer to JP-A 10-212319).
However, an &agr;-olefin polymer obtained by polymerization using any of catalysts mentioned above does not have stereospecificity of a satisfactory level, from a viewpoint of the facts that (1) a molded article having a higher rigidity is desired particularly in the field of injection molding, and (2) rigidity of an injection-molded article is increased with increase in stereospecificity of a polymer to be used.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a process for producing a catalyst for &agr;-olefin polymerization, which catalyst has a high polymerization activity and a stereospecificity polymerization ability of a high level so that removal of an amorphous polymer is not needed.
Another object of the present invention is to provide a process for producing a solid catalyst component used for the production of such a catalyst.
A further object of the present invention is to provide a process for producing an &agr;-olefin polymer by using such a catalyst.
The present invention provides a process for producing a solid catalyst component (1) for &agr;-olefin polymerization, which comprises the steps of:
(1) reducing a titanium compound represented by the following formula [I] with an organomagnesium compound in the presence of an organosilicon compound having an Si—O bond, thereby obtaining a solid product, and
(2) contacting the solid product with at least one member selected from the group consisting of an electron donor compound (E1) and an organic acid halide, and a compound having a Ti-halogen bond, thereby obtaining the solid catalyst component (1) for &agr;-olefin polymerization,
wherein “a” is a number of 2 to 20, R
2
is a hydrocarbon group having 1 to 20 carbon atoms, and X
2
is a halogen atom or a hydrocarbyloxy group having 1 to 20 carbon atoms, and all of X
2
may be the same or different from one another.
The present invention also provides a process for producing a solid catalyst component (2) for &agr;-olefin polymerization, which comprises the steps of:
(1) reducing a titanium compound represented by the above formula [I] with an organomagnesium compound in the presence of an organosilicon compound having an Si—O bond and an ester compound, thereby obtaining a solid product, and
(2) contacting the solid product with at least one member selected from the group consisting of an electron donor compound (E1) and an organic acid halide, and a compound having a Ti-halogen bond, thereby obtaining the solid catalyst component (2) for &agr;-olefin polymerization.
The present invention further provides a process for producing a catalyst (1) for &agr;-olefin polymerization, which comprises the steps of:
(1) reducing a titanium compound represented by the above formula [I] with an organomagnesium compound in the presence of an organosilicon compound having an Si—O bond, thereby obtaining a solid product,
(2) contacting the solid product with at least one member selected from the group consisting of an electron donor compound (E1) and an organic acid halide, and a compound having a Ti-halogen bond, thereby obtaining a solid catalyst component (1) for &agr;-olefin polymerization, and
(3) contacting the solid catalyst component (1), an organoaluminum compound and an electron donor compound (E2) with one another, thereby obtaining the catalyst (1) for &agr;-olefin polymerization.
The present invention still further provides a process for producing a catalyst (2) for &agr;-olefin polymerization, which comprises the steps of:
(1) reducing a titanium compound represented by the above formula [I] with an organomagnesium compound in the presence of an organosilicon compound having an Si—O bond and an ester compound, thereby obtaining a solid product,
(2) contacting the solid product with at least one member selected from the group consisting of an electron donor compound (E1) and an organic acid halide, and a compound having a Ti-halogen bond, thereby obtaining a solid catalyst component (2) for &agr;-olefin polymerization, and
(3) contacting the solid catalyst component (2), an organoaluminum compound and an electron donor compound (E2) with one another, thereby obtaining the catalyst (2) for &agr;-olefin polymerization.
The present invention additionally provides a process for producing an &agr;-olefin polymer, which comprises the steps of:
(1) reducing a titanium compound represented by the above formula [I] with an organomagnesium compound in the presence of an organosilicon compound having an Si—O bond compound, thereby obtaining a solid product,
(2) contacting the solid product with at least one member selected from the group consisting of an electron donor compound (E1) and an organic acid halide, and a compound having a Ti-halogen bond, thereby obtaining a solid catalyst component (1) for &agr;-olefin polymerization,
(3) contacting the solid catalyst component (1), an organoaluminum compound and an electron donor compound (E2) with one another, thereby obtaining a catalyst (1) for &agr;-olefin polymerization, and
(4) subjecting an &agr;-olefin to homopolymerization or copolymerization in the presence of the catalyst (1).
The present invention still additionally provides a process for producing an &agr;-olefin polymer, which comprises the steps of:
(1) reducing a titanium compound represented by the above formula [I] with an organomagnesium compound in the presence of an organosilicon compound having an Si—O bond and an ester compound, thereby obtaining a solid product,
(2) contacting the solid product with at least one member selected from the group consisting of an electron donor compound (E1) and an organic acid halide, and a compound having a Ti-halogen bond, thereby obtaining a solid catalyst component (2) for &agr;-olefin polymerization,
(3) contacting
Fujiwara Yasuki
Satoh Makoto
Choi Ling-Siu
Stevens Davis Miller & Mosher L.L.P.
Sumitomo Chemical Company Limited
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