Catalyst – solid sorbent – or support therefor: product or process – Catalyst or precursor therefor – Organic compound containing
Reexamination Certificate
2000-12-21
2003-07-01
Harlan, Robert D. (Department: 1713)
Catalyst, solid sorbent, or support therefor: product or process
Catalyst or precursor therefor
Organic compound containing
C526S161000, C526S171000
Reexamination Certificate
active
06586356
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a catalyst component for addition polymerization, a catalyst for addition polymerization made by using thereof, and a process for producing an addition polymer.
2. Description of Related Arts
Since olefin polymers such as polypropylene and polyethylene are excellent in mechanical properties, chemical resistance and the like and excellent in balance between those properties and economical efficiency, they have been widely used for various molding fields. These olefin polymers have been conventionally produced by polymerizing an olefin using a conventional type solid catalyst (multi-site catalyst) which combines a solid catalyst component obtained by using a metal compound of Group IV such as titanium trichloride or titanium tetrachloride, with a metal compound of Group XIII represented by an organoaluminum compound.
A process for producing an addition polymer, which polymerizes an addition-polymerizable monomer using a so-called single site catalyst prepared by combining a transition metal compound which is different from a solid catalyst component having been used from old (for example, a metallocene complex) with an aluminoxane or the like, is recently proposed. For example, JP-A-58-19309 reports a process using bis(cyclopentadienyl) zirconium dichloride and methyl aluminoxane. Further, it is reported that a specific boron compound and such transition metal compound are combined. For example, JP-A-1-50203 reports a process using bis(cyclopentadienyl)zirconium dimethyl and tri(n-butyl)ammonium tetrakis(pentafluorophenyl)borate. The olefin polymers obtained by using these single site catalysts have a narrower molecular weight distribution than that obtained by the conventional type solid catalyst (multi-site catalyst), and further, a comonomer is more homogeneously copolymerized in case of a copolymer. Accordingly, it is known that a more homogeneous copolymer than a case of using the conventional type solid catalyst is obtained.
The improvement of such catalyst component for addition polymerization has been intensively studied, and the kinds of metals used for main catalyst components are widely reported over the respective Groups of the Periodic Table. For example, in Angew. Chem. Int. Ed. 38 428 (1999), it reported that a metallocene complex of the Group III to the Group XIII and non-metallocene compound are effective as the main catalyst components. On the other hand, as a co-catalyst component as an activator for combining with the metallocene complex or non-metallocene compound, an aluminoxane belonging to a compound of the Group XIII, a boron compound and the like have been mainly developed.
Further, when an addition polymer such as an olefin polymer is produced using a single-site catalyst, the molecular weight of the addition polymer obtained is usually low, and the improvement thereof has been desired. JP-A-6-329713 reports a catalyst component of polymerizing an olefin composed of an aluminum compound having an electron withdrawing group or a group containing an electron withdrawing group. An olefin polymer having a certain degree of high molecular weight can be obtained by using the aluminum compound. However, since it cannot be always said that the high molecular weight is adequately high, a novel catalyst component as an activator, which realizes the further improvement of high molecular weight, has been desired.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a compound capable of forming a catalyst for addition polymerization which reveals a high polymerization activity by using as a catalyst aid component for activation and a production method thereof, a catalyst component for addition polymerization composed of a compound, capable of forming a catalyst for addition polymerization which reveals a high polymerization activity, a catalyst for addition polymerization which is made by using the catalyst component and reveals a high polymerization activity, and an efficient process for producing an addition polymer using the catalyst for addition polymerization.
Namely, according to the present invention, an electron withdrawing group-containing metal compound (I) selected from the group consisting of [A] to [E] described below, a catalyst component for addition polymerization composed of the compound(I), a catalyst for addition polymerization prepared by contacting a transition metal complex (II) therewith or by contacting a transition metal complex (II) and an organoaluminum compound(III) therewith, and a process for producing an addition polymer with the catalyst for addition polymerization are provided:
[A] A compound obtained by contacting (a), (b) and (c) described below in the presence of an ether compound as a solvent:
(a) a compound represented by the general formula [1],
M
1
L
1
c [1]
(b) a compound represented by the general formula [2],
R
1
p-1
T
1
H [2], and
(c) a compound represented by the general formula [3],
R
2
q-2
J
1
H
2
[3]
(wherein in each of the general formulae [1] to [3], M
1
represents an atom of the Group III to the Group XII or lanthanide series of the Periodic Table; c represents a valence of M
1
; L
1
represents a hydrogen atom, a halogen atom or a hydrocarbon group; when a plural number of L
1
's exist, they may be mutually the same or different; R
1
represents an electron-withdrawing group or a group containing an electron-withdrawing group; R
2
represents a hydrocarbon group or a halogenated hydrocarbon group; when a plural number of R
2
's exist, they may be mutually the same or different; each of T
1
and J
1
independently represents an atom of Group XV or Group XVI of the Periodic Table; and each of p and q represents a valence of T
1
and J
1
, respectively.);
[B] A compound obtained by contacting (d), (e) and (f) described below:
(d) a compound represented by the general formula [4],
M
2
L
2
d [4]
(e) a compound represented by the general formula [5],
R
3
r-1
T
2
H [5], and
(f) a compound represented by the general formula [6];
R
4
(J
2
H
e-1
)
f
[6]
(wherein in each of the general formulae [4] to [6], M
2
represents an atom of Group III to Group XII or lanthanide series of the Periodic Table; d represents a valence of M
2
; L
2
represents a hydrogen atom, a halogen atom or a hydrocarbon group; when a plural number of L
2
's exist, they may be mutually the same or different; R
3
represents an electron-withdrawing group or a group containing an electron-withdrawing group; R
4
represents an organic group having a valence of f; each of T
2
and J
2
independently represents an atom of the Group XV or Group XVI of the Periodic Table; r represents a valence of T
2
; e represents a valence of J
2
; and “f” is an integer of 2 to 10.);
[C] A compound represented by the general formula [7]:
(wherein M
3
represents an atom of the Group III to Group XII or lanthanide series of the Periodic Table; when a plural number of M
3
's exist, they may be mutually the same or different; T
3
represents an atom of the Group XIV, Group XV or Group XVI of the Periodic Table; when a plural number of T
3
's exist, they may be mutually the same or different; R
5
represents an electron-withdrawing group or a group containing an electron-withdrawing group; when a plural number of R
5
's exist, they may be mutually the same or different; R
6
represents a hydrocarbon group; a plural number of R
6
's may be mutually the same or different; “g” represents a valence of M
3
; “s” represents a valence of T
3
; and “h” represents a numeral of 1 or more.);
[D] A compound represented by the general formula [8],
M
4
(X
1
R
7
i
)
t
R
8
j-t
[8]
(wherein M
4
represents an atom of the Gr
Miyatake Tatsuya
Takaoki Kazuo
Birch & Stewart Kolasch & Birch, LLP
Harlan Robert D.
Sumitomo Chemical Company Limited
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