&agr;-olefins and olefin polymers and processes therefor

Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Polymers from only ethylenic monomers or processes of...

Reexamination Certificate

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C526S329000, C526S331000, C430S199000, C430S252000, C430S964000, C428S036900, C521S038000, C521S149000

Reexamination Certificate

active

06310163

ABSTRACT:

FIELD OF THE INVENTION
The invention concerns novel homo- and copolymers of ethylene and/or one or more acyclic olefins, and/or selected cyclic olefins, and optionally selected ester, carboxylic acid, or other functional group containing olefins as comonomers; selected transition metal containing polymerization catalysts; and processes for making such polymers, intermediates for such catalysts, and new processes for making such catalysts. Also disclosed herein is a process for the production of linear alpha-olefins by contacting ethylene with a nickel compound of the formula [DAB] NiX
2
2
wherein DAB is a selected &agr;-diimine and X is chlorine, bromine, iodine or alkyl, and a selected Lewis or Bronsted acid, or by contacting ethylene with other selected &agr;-diimine nickel complexes.
BACKGROUND OF INVENTION
Homo- and copolymers of ethylene (E) and/or one or more acyclic olefins, and/or cyclic olefins, and/or substituted olefins, and optionally selected olefinic esters or carboxylic acids, and other types of monomers, are useful materials, being used as plastics for packaging materials, molded items, films, etc., and as elastomers for molded goods, belts of various types, in tires, adhesives, and for other uses. It is well known in the art that the structure of these various polymers, and hence their properties and uses, are highly dependent on the catalyst and specific conditions used during their synthesis. In addition to these factors, processes in which these types of polymers can be made at reduced cost are also important. Therefore, improved processes for making such (new) polymers are of interest. Also disclosed herein are uses for the novel polymers.
&agr;-Olefins are commercial-materials being particularly useful as monomers and as chemical intermediates. For a review of &agr;-olefins, including their uses and preparation, see B. Elvers, et al., Ed., Ullmann's Encyclopedia of Industrial Chemistry, 5th Ed., Vol. A13, VCH Verlagsgesellschaft mbH, Weinheim, 1989, p. 238-251. They are useful as chemical intermediates and they-are often made by the oligomerization of ethylene using various types of catalysts. Therefore catalysts which are capable or forming &agr;-olefins from ethylene are constantly sought.
SUMMARY OF THE INVENTION
This invention concerns a polyolefin, which contains about 80 to about 150 branches per 1000 methylene groups, and which contains for every 100 branches that are methyl, about 30 to about 90 ethyl branches, about 4 to about 20 propyl branches, about 15 to about 50 butyl branches, about 3 to about 15 amyl branches, and about 30 to about 140 hexyl or longer branches.
This invention also concerns a polyolefin which contains about 20 to about 150 branches per 1000 methylene groups, and which contains for every 100 branches that are methyl, about 4 to about 20 ethyl branches, about 1 to about 12 propyl branches, about 1 to about 12 butyl branches, about 1 to about 10 amyl branches, and 0 to about 20 hexyl or longer branches.
Disclosed herein is a polymer, consisting essentially of repeat units derived from the monomers, ethylene and a compound of the formula CH
2
=CH (CH
2
)
m
CO
2
R
1
, wherein R
1
is hydrogen, hydrocarbyl or substituted hydrocarbyl, and m is 0 or an integer from 1 to 16, and which contains about 0.01 to about 40 mole percent of repeat units derived from said compound, and provided that said repeat units derived from said compound are in branches of the formula —CH(CH
2
)
n
C
0
2
R
1
, in about 30 to about 70 mole percent of said branches n is 5 or more, in about 0 to about 20 mole percent n is 4, in about 3 to 60 mole percent n is 1, 2 and 3, and in about 1 to about 60 mole percent n is 0.
This invention concerns a polymer of one or more alpha-olefins of the formula CH
2
=CH(CH
2
)
a
H wherein a is an, integer of 2 or more, which contains the structure (XXV)
wherein R
35
is an alkyl group and R
36
is an alkyl group containing two or more carbon atoms, and provided that R
35
is methyl in about 2 mole percent or more of the total amount of (XXV) in said polymer.
This invention also includes a polymer of one or more alpha-olefins of the formula CH
2
=CH(CH
2
)
a
H wherein a is an integer of 2 or more, wherein said polymer contains methyl branches and said methyl branches comprise about 25 to about 75 mole percent of the total branches.
This invention also concerns a polyethylene containing the structure (XXVII) in an amount greater than can be accounted for by end groups, and preferably at least 0.5 or more of such branches per 1000 methylene groups than can be accounted for by end groups.
This invention also concerns a polypropylene containing one or both of the structures (XXVIII) and (XXIX) and in the case of (XXIX) in amounts greater than can be accounted for by end groups. Preferably at least 0.5 more of (XXIX) branches per 1000 methylene groups than can be accounted for by end groups, and/or at least 0.5 more of (XXVIII) per 1,000 methylene groups are present in the polypropylene.
Also described herein is an ethylene homopolymer with a density of 0.66 g/ml or less.
Described herein is a process for the polymerization of olefins, comprising, contacting a transition metal complex of a bidentate ligand selected from the group consisting of
with an olefin wherein:
said olefin is selected from the group consisting of ethylene, an olefin of the formula R
17
CH=CH
2
or R
17
CH=CHR
17
, cyclobutene, cyclopentene, norbornene, or substituted norbornene;
said transition metal is selected from the group consisting of Ti, Zr, Sc, V, Cr, a rare earth metal, Fe, Co, Ti or Pd;
R
2
and R
5
are each independently hydrocarbyl or substituted hydrocarbyl, provided that the carbon atom bound to the imino nitrogen atom has at least two carbon atoms bound to it;
R
3
and R
4
are each independently hydrogen, hydrocarbyl, substituted hydrocarbyl, or R
3
and R
4
taken together are hydrocarbylene substituted hydrocarbylene to form a carbocyclic ring;
R
44
is hydrocarbyl or substituted hydrocarbyl, and R
28
is hydrogen, hydrocarbyl or substituted hydrocarbyl or R
44
and R
28
taken together form a ring;
R
45
is hydrocarbyl or substituted hydrocarbyl, and R
29
is hydrogen, substituted hydrocarbyl or hydrocarbyl, or R
45
and R
29
taken together form a ring;
each R
30
is independently hydrogen, substituted hydrocarbyl or hydrocarbyl, or two of R
30
taken together form a ring;
R
20
and R
23
are independently hydrocarbyl or substituted hydrocarbyl;
R
21
and R
22
are each in independently hydrogen, hydrocarbyl or substituted hydrocarbyl;
each R
17
is independently hydrocarbyl or substituted hydrocarbyl provided that any olefinic bond in said olefin is separated from any other olefinic bond or aromatic ring by a quaternary carbon atom or at least two saturated carbon atoms;
n is 2 or 3;
R
1
is hydrogen, hydrocarbyl or substituted hydrocarbyl;
and provided that:
said transition metal also has bonded to it a ligand that may be displace by said olefin or add to said olefin;
when M is Pd, said bidentate ligand is (VIII), (XXXII) or (XXIII);
when M is Pd a diene is not present; and
when norbornene or substituted norbornene is used no other olefin is present.
Described herein is a process for the copolymerization of an olefin and a fluorinated olefin, comprising, contacting a transition metal complex of a bidentate ligand selected from the group consisting of
with an olefin, and a fluorinated olefin wherein:
said olefin is selected from the group consisting of ethylene and an olefin of the formula R
17
CH=CH
2
or R
17
CH=CHR
17
;
said transition metal is selected from the group consisting of Ni and Pd;
said fluorinated olefin is of the formula H
2
C=CH(CH
2
)
a
R
f
R
42
;
a is an integer of 2 to 20; R
f
is perfluoroalkylene optionally containing one or more ether groups;
R
42
is fluorine or a functional group;
R
2
and R
5
are each independently hydrocarbyl or substituted hydrocarbyl, provided that the carbon atom bound to the imino nitrogen atom hap at least two

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