Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Polymers from only ethylenic monomers or processes of...
Reexamination Certificate
2002-12-17
2004-01-20
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...
C526S142000, C526S352000, C526S125100, C526S119000, C502S103000, C502S118000, C502S125000, C502S127000, C502S126000
Reexamination Certificate
active
06680360
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a process for producing a catalyst for &agr;-olefin polymerization and a process for producing an &agr;-olefin polymer.
BACKGROUND OF THE INVENTION
As disclosed in JP-A 57-63310, JP-A 58-83006 and JP-A 61-78803, there is known a process for obtaining a highly stereoregular polymer by polymerizing an &agr;-olefin in the presence of a catalyst comprising a combination of the following catalyst components:
(1) a support type solid catalyst component obtained by supporting a tetravalent titanium halide compound on a magnesium halide,
(2) an organoaluminum compound (co-catalyst) and
(3) an organosilicon compound (third component).
Further, as disclosed in JP-A7-216017, there is also known a process for obtaining a highly stereoregular polymer by polymerizing an &agr;-olefin in the presence of a catalyst comprising a combination of the following catalyst components:
(1) a solid catalyst component obtained according to a process comprising the steps of:
(i) reducing a titanium compound with an organomagnesium compound in the presence of an organosilicon compound and an ester compound to obtaining a solid product,
(ii) treating said solid product with an ester compound, and
(iii) treating the treated product with either a mixture of an ether compound and titanium tetrachloride, or a mixture of an ether compound, titanium tetrachloride and an ester compound to obtain the desired solid catalyst component containing a trivalent titanium compound,
(2) an organoaluminum compound (co-catalyst) and
(3) an organosilicon compound (third component).
Furthermore, as disclosed in JP-A 10-212319, there is also known a process for obtaining a highly stereoregular polymer by polymerizing an &agr;-olefin in the presence of a catalyst comprising a combination of the following catalyst components:
(1) a solid catalyst component obtained according to a process comprising the steps of:
(i) reducing a titanium compound with an organomagnesium compound in the presence of an organosilicon compound and an ester compound to obtain a solid product,
(ii) treating said solid product with a mixture of an ether compound and titanium tetrachloride,
(iii) further treating the treated product with an organic acid halide compound, and
(iv) still further treating the resulting treated product with either a mixture of an ether compound and titanium tetrachloride, or a mixture of an ether compound, titanium tetrachloride and an ester compound to obtain the desired solid catalyst component containing a trivalent titanium compound,
(2) an organoaluminum compound (co-catalyst) and
(3) an organosilicon compound (third component).
According to the above-mentioned processes, a highly stereoregular polymer can be produced through a no-extraction
o-deash process. However, it is desired to further improve a quality of the highly stereoregular polymer.
SUMMARY OF THE INVENTION
Objects of the present invention are to provide a process for producing a polymerization catalyst suitable for obtaining a high quality &agr;-olefin polymer, and to provide a process for producing such an &agr;-olefin polymer.
The present invention provides a process for producing a catalyst for &agr;-olefin polymerization, which comprises the step of contacting (1) a solid catalyst component having Ti, Mg and a halogen as essential components, (2) an organoaluminum compound and (3) a compound having a —C—O—C—O—C— bond group in a closed ring structure with one another.
The present invention also provides a process for producing a catalyst for &agr;-olefin polymerization, which comprises the step of contacting (1) a solid catalyst component having Ti, Mg and a halogen as essential components, (2) an organoaluminum compound, (3) a compound having a —C—O—C—O—C— bond group and (4) an alkoxysilicon compound with one another.
The present invention also provides a process for producing a catalyst for &agr;-olefin polymerization, which comprises the step of contacting (1) a solid catalyst component having Ti, Mg and a halogen as essential components, (2) an organoaluminum compound, (3) a compound having a —C—O—C—O—C— bond group and (4) a 1,3-diether compound with one another.
The present invention also provides a process for producing a catalyst for &agr;-olefin polymerization, which comprises the step of contacting (1) a solid catalyst component having Ti, Mg and a halogen as essential components, (2) an organoaluminum compound, (3) a compound having a —C—O—C—O—C— bond group and (4) a piperidine compound with one another.
The present invention further provides a process for producing an &agr;-olefin polymer, which comprises the step of homopolymerizing or copolymerizing an &agr;-olefin in the presence of a catalyst for &agr;-olefin polymerization, which catalyst is obtained according to any of the above-mentioned processes for producing a catalyst for &agr;-olefin polymerization.
DETAILED DESCRIPTION OF THE INVENTION
The compound having a —C—O—C—O—C— bond group in a closed ring structure used in the present invention is a compound used as a so-called external donor. As such a compound, a compound represented by the following formula is exemplified. In the formula, R
2
to R
7
are independently of one another a hydrogen atom, a hydrocarbon group having 1 to 20 carbon atoms or a hydrocarbyloxy group having 1 to 20 carbon atoms; and R
1
and R
8
are independently of each other a hydrocarbon group having 1 to 20 carbon atoms or a hydrocarbyloxy group having 1 to 20 carbon atoms, wherein both groups represented by R
1
and R
8
are bound with each other, or a left end carbon atom to which R
1
is bound and a right end carbon atom to which R
8
is bound are directly bound (in the latter case, neither R
1
nor R
8
exists).
Examples of R
2
to R
7
are a hydrogen atom, a methyl group, an ethyl group, a n-propyl group, an i-propyl group, a n-butyl group, an i-butyl group, a tert-butyl, a n-pentyl group, an 1-pentyl group, a neopentyl group, a cyclopentyl group, a n-hexyl group, an 1-hexyl group, a cyclohexyl group, a n-heptyl group, a n-octyl group, 2-ethylhexyl group, a n-decyl group, an i-decyl group, a phenyl group, a methoxy group, an ethoxy group, a n-propoxy group, an i-propoxy group, a n-butoxy group, an i-butoxy group, a tert-butoxy group, a n-pentoxy group, an i-pentoxy group, a neopentoxy group, a n-hexoxy group and an i-hexoxy group.
Examples of a preferable compound represented by the above formula are 1,3-dioxolan, 2-methyl-1,3-dioxolan, 4-methyl-1,3-dioxolan, 2,2-dimethyl-1,3-dioxolan, 2,4-dimethyl-1,3-dioxolan, 2-methoxy-1,3-dioxolan, 4-methoxy-1,3-dioxolan, 2,2-dimethoxy-1,3-dioxolan, 1,3-dioxane, 2-methyl-1,3-dioxane, 4-methyl-1,3-dioxane, 2,2-dimethyl-1,3-dioxane, 2,4-dimethyl-1,3-dioxane, 2-methoxy-1,3-dioxane, 4-methoxy-1,3-dioxane, 2,2-dimethoxy-1,3-dioxane, 2,4-dimethoxy-1,3-dioxane, 1,3-dioxepane, 2-methyl-1,3-dioxepane, 4-methyl-1,3-dioxepane, 5-methyl-1,3-dioxepane, 2,4-dimethyl-1,3-dioxepane, 2,5-dimethyl-1,3-dioxepane, 2-methoxy-1,3-dioxepane, 4-methoxy-1,3-dioxepane, 5-methoxy-1,3-dioxepane and s-trioxane. Among them, particularly preferable is 1,3-dioxolan, 1,3-dioxane, 1,3-dioxepane or s-trioxane.
The compound having a —C—O—C—O—C— bond group used in the present invention is a compound used as a so-called external donor. As such a compound, a compound represented by the above formula is exemplified. In the formula, R
1
to R
8
are independently of one another a hydrogen atom, a hydrocarbon group having 1 to 20 carbon atoms or a hydrocarbyloxy group having 1 to 20 carbon atoms. Any groups represented by R
1
to R
8
may be bound with one another, and any two of three carbon atoms to which R
1
to R
8
are bound may be directly bound with each other. For example, a central carbon atom to which R
4
is bound and a right end carbon atom to which R
6
is bound may be directly bound with each other. In this case, neither R
4
nor R
6
exists. Examples of R
1
to R
8
are similar to those exemplified for the above-mentioned R
2
to R
7
.
Examples of a compound wherein any combination of R
1
Choi Ling-Siu
Sughrue & Mion, PLLC
Sumitomo Chemical Company Limited
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