SILOXY-SUBSTITUTED MONOCYCLOPENTADIENYL LIGATED CONSTRAINED GEOMETRY OLEFIN POL YMERISATION CATALYSTS
5 This invention relates to catalysts for olefin polymerisation, in particular to catalyst compounds containing metals η- and σ-bonded by siloxycyclopentadienyl ligands, and their use in olefin polymerisation. 10
In olefin polymerization, it has long been known to use as a catalyst system the combination of a metallocene procatalyst and an alumoxane co-catalyst.
15 By "metallocene" is here meant an η-ligand metal complex, e.g. an "open sandwich" or "half sandwich" compound in which the metal is complexed by a single η- ligand, a "sandwich" compound in which the metal is complexed by two or more η-ligands, a "handcuff"
20 compound" in which the metal is complexed by a bridged bis-η-ligand or a "scorpionate" compound in which the metal is complexed by an η-ligand linked by a bridge to a σ-ligand.
25 Alumoxanes are compounds with alternating aluminium and oxygen atoms generally compounds of formula A or B
R2A1- (O-AlR)p-O-AlRj (A)
RA1- (0-AlR)p-0-AlR (B)
30 V, O ^
where each R, which may be the same or different, is a C^o alkyl group, and p is an integer having a value between 0 and 40) . These compounds may be prepared by 35 reaction of an aluminium alkyl with water. The production and use of alumoxanes is described in the patent literature, especially the patent applications of
Texas Alkyls, Albemarle, Ethyl, Phillips, Akzo Nobel, Exxon, Idemitsu Kosan, Witco, BASF and Mitsui.
Methyl alumoxane (MAO) and butyl alumoxanes (e.g. hexaisobutylalumoxane and tetraisobutylalumoxane are preferred for use according to the present invention.
We have now surprisingly found that metallocenes in which the metal is η-liganded by a siloxy-, homo or heterocyclic cyclopentadienyl group, i.e. a cyclic η5-ligand substituted by a siloxy group but not carrying a fused ring, have surprisingly high activity with non- MAO alumoxanes .
Thus viewed from one aspect the invention provides a metallocene procatalyst compound comprising a group 3 to 7 transition metal η- and σ-liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group.
By a group 3 (etc) metal is meant a metal in group 3 of the Periodic Table of the Elements, namely Sc, Y, etc.
Viewed from a further aspect the invention provides an olefin polymerisation catalyst system comprising or produced by reaction of (i) a metallocene procatalyst compound comprising a group 3 to 7 transition metal η- and σ-liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group and (ii) a co-catalyst, eg an aluminium alkyl compound, in particular an alumoxane, especially an aluminium alkyl compound comprising alkyl groups containing at least two carbon atoms .
Viewed from a still further aspect the invention provides a process for olefin polymerisation comprising polymerising an olefin in the presence of a metallocene
compound comprising a group 3 to 7 transition metal η- and σ-liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group.
Viewed from a yet further aspect the invention provides a process for the preparation of a metallocene procatalyst, said process comprising metallating with a group 3 to 7 transition metal a ligand comprising a monocyclic, homo- or heterocyclic cyclopentadienyl group substituted on the η-ring by a siloxy group and by a group capable /of σ-bonding said metal .
Viewed from a further aspect the invention provides the use of a metallocene compound comprising a group 3 to 7 transition metal η- and σ-liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group in olefin polymerization, especially ethylene or propylene, more especially ethylene, polymerisation or copolymerisation.
Viewed from a yet further aspect the invention provides an olefin polymer produced by a polymerisation catalysed by a metallocene compound comprising a group 3 to 7 transition metal η- and σ-liganded by a siloxy substituted, monocyclic, homo- or heterocyclic cyclopentadienyl group.
By "monocyclic" it is meant that the η5 ring of the cyclopentadienyl group is not fused to another ring, ie it cannot be a part of an indenyl or fluorenyl multi- ring structure. The η5 ring however may be substituted by cyclic groups or cyclic group containing substituents and the metal may be liganded by other η-ligands which are acyclic or multicyclic.
The η
5-ligand with which the group 3 to 7 metal is complexed typically is a compound of formula IV
where X, Y and T are ring carbons or ring heteroatoms, eg N, B or P atoms, two or three of X, Y and T preferably being ring carbons; each R', which may be the same or different is a R+, OR+, SR+, NR+ 2 or PR+ 2 group where each R+ is a Cx_16 hydrocarbyl group, a tri-C,.
8hydrocarbylsiLyl group or a tri-C1_8hydrocarbylsiloxy group, preferably R' being a C1_12 hydrocarbyl group, eg a C2_8 alkyl or alkenyl group;
each R", which may be the same or different is a ring substituent which does not form a bond to a metal η- bonded by the C
2XYT ring and is other than a ring fused to the C
2XYT ring (eg a R
+, OR
+, SR
+, NR
+ 2 or PR
+ 2 group where each R
+ is a
hydrocarbylsilyl group or a tri-C
1_
ahydrocarbylsiloxy group or two R
+ groups together form a 3 to 6 atom bridge, preferably a hydrocarbyl bridge) or is an η- ligand linked to the C
2XYT ring by a 1 to 3 atom bridge, and optionally substituted, eg by R
+, OR
+, SR
+, NR
+ 2 or PR
+ 2 groups;
n is zero or a positive integer, eg having a value of 1, 2, 3 or 4, n preferably being non-zero; m is 1 or 2,preferably 1; and R"' is a group capable of σ-bonding a transition metal ion, eg a group defined as Z in WO98/06728.
In the ligand of formula IV, the σ-bonding moiety R" ' is a divalent moiety bound to the cyclopentadienyl ring by a σ-bond and capable of binding to a transition metal M via a σ-bond, preferably via a M-heteroatom bond. R" ' preferably comprises boron or a group 14 atom (eg C, Si
or Ge) and a N, 0, S or P atom. Particularly preferably, R" ' comprises a group R
aR
b with R
a attached to the cyclopentadienyl ring and R
D being capable of bonding to the metal M, where R
a provides a 1 to 3 atom bridge of group 14 atoms, eg a group SiR
c 2, CR°
2,
, CR
2SlR
2, CR
2Sl
2CR
2, SiR
c 2CR
c 2SiR
c 2, CR
c 2CR
c 2SiR
c 2, CR
C 2CR
C 2CR
C 2 or GeR
c 2, R
b is NR
C, 0, S or PR
0, and R
c is hydrogen, hydrocarbyl, hydrocarbyloxy, silyl or halohydrocarbyl or two R
c groups together form a homo- or heterocyclic ring, each R° containing up /to 20 non-hydrogen atoms. Thus the "scorpion tail" R
aR
b may contain as side chains silyl (eg trialkylsilyl) and halohydrocarbyl (eg CF
3 or perfluoro- t-butyl) groups .
Particularly preferred R" ' groups include -Si(CH3)2NRd groups where Rd is a C__^12 hydrocarbyl group, eg
-Si (CH3)2-N-t. butyl
-Si (CH3) 2-N-cyclohexyl or
-Si (CH3) 2-N-benzyl .
Besides the η-ligand of formula IV, the group 3 to 7 transition metal may be η-liganded by one or two further η ligands. These may be cyclic or acyclic and may carry cyclic groups fused to an η5 or η4 cyclic or acyclic structure and may be bridged bis-η ("handcuff") ligands or bridged η-σ ("scorpion") ligands. Thus for example such an η5 or η4 ligand group may be a homo- or heterocyclic cyclopentadienyl, indenyl or fluorenyl group, or an acyclic η5 C5, η5-C3N2 or η4C2N2 group optionally carrying cyclic groups fused to the η5 or η4 skeleton. Such further η ligands may optionally be substituted, eg by groups R".
Particular examples of such further η-ligands include cyclopentadienyl, indenyl and fluorenyl ligands, especially siloxy substituted (eg R'3SiO-substituted) cyclopentadienyl or indenyl ligands.
Examples of such further η-ligands abound in the patent literature relating to metallocene and pseudo metallocene olefin polymerization (pro) catalysts, in particular that deriving from Exxon, Hoechst, Phillips, Dow, Chisso, Mitsui, Fina, BASF, Mitsubishi, Mobil, Targor, DSM an'd Borealis, eg WO96/23010, WO98/49208, W099/12981, W099/19335, WO97/28170, EP-A-423101 and EP- A-537130 as well as "Metallocenes" , Vol 1, Togni and Halterman (Eds.), Wiley-VCH, 1998.
Besides η-ligands, the group 3 to 7 metal in the procatalyst of the invention may be coordinated by hydrogen atoms, hydrocarbyl σ-ligands (eg optionally substituted Cx_12 hydrocarbyl groups, such as C___ιz alkyl, alkenyl or alkynyl groups optionally substituted by fluorine and/or aryl (eg phenyl) groups) , by silane groups (eg Si(CH3)3), by halogen atoms (eg chlorine) , by Cι_8 hydrocarbylheteroatom groups, by tri- Ci.ghydrocarbylsilyl groups, by bridged bis-σ-liganding groups, by amine (eg N(CH3)2) or imine (eg N=C or N=P groups, eg (iPr)3P=N) groups, or by other σ-ligands known for use in metallocene (pro) catalysts.
By a σ-ligand moiety is meant a group bonded to the metal at one or more places via a single atom, eg a hydrogen, halogen, silicon, carbon, oxygen, sulphur or nitrogen atom.
Thus for example the metallocene pro catalyst of the invention may conveniently be a compound of formula V
where X, Y, T, R', R", R"', n and m are as defined above;
q is 1, 2 or 3, generally being 1 when m is 1 ; M is a group 3 to 7 transition metal
L is a further/ η-ligand (eg as discussed above) ; r is zero, 1 or 2;
Z is a σ-ligand (eg as discussed above) ; and s is zero or a positive integer having a value of up to 3 depending on the values of m, q and r and the oxidation state of metal M.
The metal M in the metallocene procatalysts of the invention is a group 3 to 7 transition metal, preferably a group 4 to 6 transition metal, eg a metal selected from Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W. However the metal is preferably Cr, Ti, Zr or Hf, particularly Cr if M is η-liganded by a single η-ligand group or Ti, Zr or Hf if M is η-liganded by one or more η-ligand groups
In the metallocene procatalysts of the invention, the siloxycyclopentadienyl η-ligand is especially preferably a ligand of formula VI
where R' is as defined above; Y' is P, B, CH or C-CH
3; R^ is H or CH
3; and R is a group R
aR as defined above
Examples of suitable R'3SiO groups in the metallocene procatalysts of the invention include
Thus typical examples of ligands of formula IV include
Typical examples of the metallocene procatalysts of the invention thus include:
Examples of particular siloxy-η-ligands usable according to the invention include:
dimethylsilanediyl (2- triisopropylsiloxycyclopentadienyl) (N-tert .butylamido) , dimethylsilanediyl (2-triisopropylsiloxy-4-methyl- cyclopentadienyl) (N-tert .butylamido) , dimethylsilanediyl (2-triisopropylsiloxy-3,4-dimethyl- cyclopentadienyl) (N-tert .butylamido) , dimethylsilanediyl (2-triisopropylsiloxy-3 , 4 , 5-trimethyl- cyclopentadienyl) (N-tert .butylamido) ,
dimethylsilanediyl (2- tert .butyl, dimethylsiloxycyclopentadienyl) (N- tert .butylamido) , dimethylsilanediyl (2-tert .butyl , dimethylsiloxy-4-methyl- cyclopentadienyl) (N-tert .butylamido) , dimethylsilanediyl (2-tert .butyl, dimethylsiloxy-3 , 4- dimethyl-cyclopentadienyl) (N-tert .butylamido) , dimethylsilanediyl (2-tert .butyl, dimethylsiloxy-3 ,4,5- trimethyl-cyclopentadienyl) (N-tert .butylamido) , dimethylsilanediyl (2-trimethylsiloxycyclopentadienyl) (N- t .butylamido) , dimethylsilanediyl (2- t .butyl, dimethylsiloxycyclopentadienyl) (N-t .butylamido) , dimethylsilanediyl (2- t .butyl, dimethylsiloxyphospholyl) (N-t .butylamido) , dimethylsilanediyl (2-t .butyl, dimethylsiloxypyrrolyl) (N- t .butylamido) , and trimethylsilylmethylsilanediyl (2- trimethylsiloxycyclopentadienyl) (N- .butylamido) .
Examples of particular further η-ligands are well known from the technical and patent literature relating to metallocene olefin polymerization catalysts, e.g. EP-A-
35242 (BASF) , EP-A-129368 (Exxon) , EP-A-206794 (Exxon) , PCT/FI97/00049 (Borealis), EP-A-318048, EP-A-643084, EP-
A-69951, EP-A-410734, EP-A-128045, EP-B-35242 (BASF) ,
EP-B-129368 (Exxon) and EP-B-206794 (Exxon) . These include
cyclopentadienyl , indenyl , fluorenyl , octahydrofluorenyl , methylcyclopentadienyl , 1 , 2-dimethylcyclopentadienyl , pentamethylcyclopentadienyl , pentyl-cyclopentadienyl ,
2-dimethyl, tertbutylsiloxy-inden-1-yl , n-butylcyclopentadienyl , 1 , 3-dimethylcyclopentadienyl , 4 , 7-dimethylindenyl , 1, -ethyl-2-methylcyclopentadienyl, tetrahydroindenyl, and methoxycyclopentadienyl .
Examples of σ-ligands include:
halogenides (e/.g. chloride and fluoride) , hydroge , triC1_12 hydrocarbyl-silyl or -siloxy(e.g. trimethylsilyl) , trices hydrocarbylphosphimido (e.g. triisopropylphosphimido) , c ι-i2 hydrocarbyl or hydrocarbyloxy (e.g. methyl, ethyl, phenyl, benzyl and methoxy) , diCi-,6 hydrocarbylamido (e.g. dimethylamido and diethylamido) , and
5 to 7 ring membered heterocyclyl (eg pyrrolyl, furanyl and pyrrolidinyl) .
The siloxy cyclopentadienyl η-σ-ligands used according to the invention may be prepared by reaction of a corresponding siloxycyclopentadiene with an organolithium compound, eg methyllithium or butyllithium. The ligand can be metallated conventionally, eg by reaction with a halide of the metal M, preferably in an organic solvent, eg a hydrocarbon or a hydrocarbon/ether mixture . The σ- bonding group R" ' may be introduced by reacting a corresponding siloxycyclopentadiene with a compound such as a hydrocarbylaminosilyl halide or a hydrocarbylaminogermyl halide. Bridged siloxy- cyclopentadienyl ligands may be constructed by reacting a siloxy-monocyclopentadienyl ligand with a bridging
agent (eg Si(CH3)2Cl2) or with a bridging agent and a further η-ligand (eg a different cyclopentadienyl ligand or with an indenyl, fluorenyl , etc ligand). σ-ligands other than chlorine may be introduced by displacement of chlorine from an η-ligand metal chloride by reaction with appropriate nucleophilic reagent (e.g. methyl lithium or methylmagnesium chloride) or using, instead of a metal halide, a reagent such as tetrakisdimethylamidotitanium or metal compounds with mixed chloro and dimethylamido ligands.
As mentioned above, the olefin polymerisation catalyst system of the invention comprises (i) a siloxycyclopentadienyl metallocene and (ii) an aluminium alkyl compound, or the reaction product thereof. While the aluminium alkyl compound may be an aluminium trialkyl (eg triethylaluminium (TEA) ) or an aluminium dialkyl halide (eg diethyl aluminium chloride (DEAC) ) , it is preferably an alumoxane, particularly an alumoxane other than MAO, most preferably an isobutylalumoxane, eg TIBAO (tetraisobutylalu oxane) or HIBAO
(hexaisobutylalumoxane) . Alternatively however the alkylated (eg methylated) metallocene procatalysts of the invention (e.g. compounds of formula V wherein Z is alkyl) may be used with other cocatalysts, eg boron compounds such as B(C6F5)3, C6H5N(CH3) 2H:B (C6F5) __ , (C6H5)3C:B(C6F5)4 or Ni (CN) 4 [B (C6F5) 3] 4 2~ .
The metallocene procatalyst and cocatalyst may be introduced into the polymerization reactor separately or together or, more preferably they are pre-reacted and their reaction product is introduced into the polymerization reactor.
If desired the procatalyst, procatalyst/cocatalyst mixture or a procatalyst/cocatalyst reaction product may be used in unsupporeted form i.e. metallocene and alumoxane can be precipitated without any actual carrier material and used as such. However the metallocene procatalyst or its reaction product with the cocatalyst is
preferably introduced into the polymerization reactor in supported form, eg impregnated into a porous particulate support .
However, the particulate support material used is preferably an organic or inorganic material, e.g. a polymer (such as for example polyethylene, polypropylene, an ethylene-propylene copolymer, another polyolefin or polystyrene or a combination thereof) . Such polymeric supports may be formed by precipitating a polymer or by a prepolymerization, eg of monomers used in the polymerization for which the catalyst is intended. However, the support is especially preferably a metal or pseudo metal oxide such as silica, alumina or zirconia or a mixed oxide such as silica-alumina, in particular silica, alumina or silica-alumina.
Particularly preferably, the support material is acidic, e.g. having an acidity greater than or equal to silica, more preferably greater than or equal to silica-alumina and even more preferably greater than or equal to alumina. The acidity of the support material can be studied and compared using the TPD (temperature programmed desorption of gas) method. Generally the gas used will be ammonia. The more acidic the support, the higher will be its capacity to adsorb ammonia gas. After being saturated with ammonia, the sample of support material is heated in a controlled fashion and the quantity of ammonia desorbed is measured as a function of temperature.
The support is a porous material so that the catalysts may be loaded into the pores of the support, e.g. using a process analogous to those described in W094/14856 (Mobil) , W095/12622 (Borealis) and WO96/00243 (Exxon) . The particle size is not critical but is preferably in the range 5 to 200 μm, more preferably 20 to 80 μm.
Before loading, the particulate support material is preferably calcined, ie heat treated, preferably under a
non-reactive gas such as nitrogen. This treatment is preferably at a temperature in excess of 100°C, more preferably 200°C or higher, e.g. 200-800°C, particularly about 300°C. The calcination treatment is preferably effected for several hours, e.g. 2 to 30 hours, more preferably about 10 hours.
The support may also be treated with an alkylating agent before being loaded with the catalysts. Treatment with the alkylating agent may be effected using an alkylating agent in a gas or liquid phase, e.g. in an organic solvent for the alkylating agent. The alkylating agent may be any agent capable of introducing alkyl groups, preferably Cx.6 alkyl groups and most especially preferably methyl groups. Such agents are well known in the field of synthetic organic chemistry. Preferably the alkylating agent is an organometallic compound, especially an organoaluminium compound (such as trimethylaluminium (TMA) , dimethyl aluminium chloride, triethylaluminium) or a compound such as methyl lithium, dimethyl magnesium, triethylboron, etc. The quantity of alkylating agent used will depend upon the number of active sites on the surface of the carrier. Thus for example, for a silica support, surface hydroxyls are capable of reacting with the alkylating agent. In general, an excess of alkylating agent is preferably used with any unreacted alkylating agent subsequently being washed away.
Where an organoaluminium alkylating agent is used, this is preferably used in a quantity sufficient to provide a loading of at least 0.1 mmol Al/g carrier, especially at least 0.5 mmol Al/g, more especially at least 0.7 mmol Al/g, more preferably at least 1.4 mmol Al/g carrier, and still more preferably 2 to 3 mmol Al/g carrier. Where the surface area of the carrier is particularly high, lower aluminium loadings may be used. Thus for example particularly preferred aluminium loadings with a surface area of 300-400 m2/g carrier may
range from 0.5 to 3 mmol Al/g carrier while at surface areas of 700-800 m2/g carrier the particularly preferred range will be lower.
Following treatment of the support material with the alkylating agent, the support is preferably removed from the treatment fluid and any excess treatment fluid is allowed to drain off.
The optionally alkylated support material is loaded with the catalysts, preferably using a solution of the catalyst (s) in an organic solvent therefor, e.g. as described in the patent publications referred to above. Preferably, the volume of catalyst solution used is from 50 to 500% of the pore volume of the carrier, more especially preferably 80 to 120%. The concentration of catalyst compound in the solution used can vary from dilute to saturated depending on the amount of catalytically active sites that it is desired be loaded into the carrier pores.
The active metals (ie. the metals of the catalysts) are preferably loaded onto the support material at from 0.1 to 4%, preferably 0.5 to 3.0%, especially 1.0 to 2.0%, by weight metal relative to the dry weight of the support material .
After loading of the catalysts onto the support material, the loaded support may be recovered for use in olefin polymerization, e.g. by separation of any excess catalyst solution and if desired drying of the loaded support, optionally at elevated temperatures, e.g. 25 to 80°C. As mentioned above, a cocatalyst, e.g.- an alumoxane or an ionic catalyst activator (such as a boron or aluminium compound, especially a fluoroborate) may also be mixed with or loaded onto the catalyst support material. This may be done subsequently or more preferably simultaneously to loading of the catalysts, for example by including the cocatalyst in the solution of the catalyst or, by contacting the catalyst loaded
support material with a solution of the cocatalyst or catalyst activator, e.g. a solution in an organic solvent. Alternatively however any such further material may be added to the catalyst loaded support material in the polymerization reactor or shortly before dosing of the catalyst material into the reactor.
However, an alternative to using an alumoxane is to use a fluoroborate catalyst activacor, especially a B(C6F5)3 or more especially a ΘB(C6F5)4 compound, such as C6H5N(CH3)2H:B(C6F5)4 or (C6H5) 3C :B (C6F5) 4. Other borates of general formula (cation+)a (borate")b where a and b are positive numbers, may also be used.
Where such a cocatalyst or catalyst activator is used, it is preferably used in a mole ratio to the catalytically active metal of from 0.1:1 to 10000:1, especially 1:1 to 50:1, particularly 1:2 to 30:1. More particularly, where an alumoxane cocatalyst is used, then the aluminium: catalyst metal (M) molar ratio is conveniently 2:1 to 10000:1, preferably 50:1 to 400:1. Where a borane cocatalyst (catalyst activator) is used, the B:M molar ratio is conveniently 2:1 to 1:2, preferably 9:10 to 10:9, especially 1:1. When a neutral triarylboron type cocatalyst is used the B:M molar ratio is typically 1:2 to 500:1, however some aluminium alkyl would normally also be used. When using ionic tetraaryl borate compounds, it is preferred to use carbonium rather than ammonium counterions or to use B:M molar ratio 1:1 or below.
Where the further material is loaded onto the catalyst loaded support material, the support may be recovered and if desired dried before use in olefin polymerization.
The olefin polymerized in the method of the invention is preferably ethylene or an alp a-olefin or a mixture of ethylene and an α-olefin or a mixture of alpha olefins, for example C2_20 olefins, e.g. ethylene, propene, n-but-1-ene, n-hex-1-ene, 4-methyl-pent-1-ene,
n-oct-1-ene- etc. The olefins polymerized in the method of the invention may include any compound which includes unsaturated polymerizable groups. Thus for example unsaturated compounds, such as C6_20 olefins (including cyclic and polycyclic olefins (e.g. norbornene)), and polyenes, especially C6-.20 dienes, may be included in a comonomer mixture with lower olefins, e.g. C2_5 a~ olefins.
In general, where the polymer being produced is a homopolymer it will preferably be polyethylene or polypropylene/ Where the polymer being produced is a copolymer it will likewise preferably be an ethylene or propylene copolymer with ethylene or propylene making up the major proportion (by number and more preferably by weight) of the monomer residues. Comonomers, such as C4_6 alkenes, will generally be incorporated to contribute to the mechanical strength of the polymer product .
Using the catalysts of the invention the nature of the monomer/monomer mixture and the polymerization conditions may be changed during the polymerization process so as to produce a desired molecular weight distribution, e.g. a broad bimodal or multimodal molecular weight distribution (MWD) in the final polymer product. In such a broad MWD product, the higher molecular weight component contributes to the strength of the end product while the lower molecular weight component contributes to the processability of the product, e.g. enabling the product to be used in extrusion and blow moulding processes, for example for the preparation of tubes, pipes, containers, etc.
MWD control in the method of the invention may be acheived by controlling the monomer (e.g. ethylene) and preferably also hydrogen partial pressure) . Typically hydrogen concentration may be varied up to 5%, more preferably up to 1%, of the gas phase in the polymerisation reactor. To acheive MWD control by
varying monomer concentration the polymerization reaction may be affected at atmospheric or subatmospheric monomer pressure to acheive low molecular weight polymer production by the titanium catalyst and at pressure in the range of atmospheres (e.g. 10 to 50 bar, preferably 20 to 45 bar) to acheive production of very high molecular weight polymers by the titanium catalyst.
Polymerization in the method of the invention may be effected in-' one or more, e.g. 1, 2 or 3, polymerization reactors, using conventional polymerization techniques, e.g. gas phase, solution phase, slurry or bulk polymerization, most preferably gas phase polymerization.
In general, a combination of slurry (or bulk) and at least one gas phase reactor is often preferred, particularly with the reactor order being slurry (or bulk) then one or more gas phase . For slurry reactors, the reaction temperature will generally be in the range 60 to 110°C (e.g. 85-110°C) , the reactor pressure will generally be in the range 5 to 80 bar (e.g. 50-65 bar), and the residence time will generally be in the range 0.3 to 5 hours (e.g. 0.5 to 2 hours) . The diluent used will generally be an aliphatic hydrocarbon having a boiling point in the range -70 to +100°C. In such reactors, polymerization may if desired be effected under supercritical conditions .
For gas phase reactors, the reaction temperature used will generally be in the range 60 to 115°C (e.g. 70 to 110°C) , the reactor pressure will generally be in the range 10 to 25 bar, and the residence time will generally be 1 to 8 hours. The gas used will commonly be a non-reactive gas such as nitrogen together with monomer (e.g. ethylene).
For solution phase reactors, the reaction temperature used will generally be in the range 130 to
270°C, the reactor pressure will generally be in the range 20 to 400 bar and the residence time will generally be in the range 0.1 to 1 hour. The solvent used will commonly be a hydrocarbon with a boiling point in the range 80-200°C.
Generally the quantity of catalyst used will depend upon the nature of the catalyst, the reactor types and conditions and the properties desired for the polymer product. Conventional catalyst quantities, such as described in the publications referred to herein, may be used. L
All publications referred to herein are hereby incorporated by reference.
The invention will now be illustrated further by reference to the following non-limiting Examples and to the accompanying drawings in which:
The invention will now be illustrated further by reference to the following non-limiting Examples:
Ligand and complex synthesis
All operations are carried out in an argon or nitrogen atmosphere using standard Schlenk, vacuum and drybox techniques. Ether, tetrahydrofuran (THF) and toluene solvents were dried with potassium benzophenone ketyl and distilled under argon prior to use. Other solvents were dried using 13X+13A molecular sieves. All other chemicals were used as commercially available.
NMR spectra were recorded using a JEOL JNM-EX270 MHz FT- NMR spectrometer with trimethylsilane (TMS) as an internal reference .
Direct inlet mass spectra were recorded using a VG TRIO 2 quadrupole mass spectrometer in electron impact ionization mode (70eV) .
GC-MS analysis was performed using a Hewlett Packard 6890/5973 Mass Selective Detector in electron impact ionization mode (70eV) , equipped with a silica capillary column (30m x 0.25 mm i.d).
Ligand preparation was based on known procedures, eg as described in Organometallics 15.: 5066-86 (1996) and in Bull. Soc. Chem. Fr 2981-91 (1970).
Alumoxanes
MAO (30wt% in toluene) and HIBAO (70wt% in toluene) from Albermarle were used.
Example 1
Dimethylsilanediyl (1- (2-t-butyldimethylsiloxy-3 , 4, 5- trimethylcyclopentadienyl) (N-tert .butylamido) titanium dichloride
(a) Synthesis of 2, 3 ,4-trimethyl-5-
(tert .butyl, dimethylsiloxy) -cyclopentadienyl lithium
7.06g (29.6mmol) of 2, 3 , 4-trimethyl-l- (tert.butyl, dimethylsiloxy) -cyclopentadiene (prepared analogously to the descriptions in Bull. Soc. Chem. Fr. 2981-2991(1970) and Organometallics 15:5066-5086 (1996) ) was dissolved in lOOmL of dry heptane at ambient temperature. 6.44mL (62.1mmol) of dimethoxyethane (DME) was added to the solution in one portion using a
syringe. The solution was cooled to -40oC and 19.7mL (29.6mmol) of 1.5M tert.butyl lithium was added over five minutes. The light yellow mixture was stirred overnight at ambient temperature. After 16 hours stirring, a pale yellow precipitate had formed and this was filtered and washed with 3x8OmL of dry pentane . The solvents were removed under vacuum yielding a pale yellow solid. Yield 6.68g (92.4%).
-NMR (THF-d8) :δ 4.83 (s, IH) , 1.96 (s, 3H) , 1.92 (s, 3H) , 1.90(s,3H), 0,98(8, 9H) , 0.07(s, 6H) . The product decomposed during EIMS analysis .
(b) Synthesis of 1-chloro-N-t .butyl-1, 1- dimethylsilanamine
n-Butyl lithium (22.3mL, 60.3mmol) was added dropwise over 5 minutes into a solution of tert .butylamine (4.41g, 60.3mmol) in 50mL of dry tetrahydrofuran (THF) at ambient temperature. The resulting solution was refluxed for 3 hours. Then dimethylsilyldichloride (7.4mL, 60.3mmol) dissolved in 50mL of dry THF was added over 10 minutes at 25oC. The solution was stirred overnight at 50oC and a whitish precipitate formed. The precipitate was filtered off and washed with 2x2OmL of THF. The solvents were removed by distillation at atmospheric pressure and the product was further purified by distillation in vacuum to yield 10.45g of a hazy colorless liquid, 68.1% pure containing only THF as impurity. BP 75-89oC/lO-20mbar. Yield 7. lg (71.1%).
1H-NMR(C6D6) :δ 1.26 (s,9H), 0.46 (s.6H).
13C-NMR ( C6D6) : δ 33 . 45 , 26 . 14 , 4 . 77 .
(c) Synthesis of ( (2-tert .butyl, dimethylsiloxy-3 , 4, 5- trimethylcyclopentadienyl) -dimethylsilyl) tert .butylamine
1-Chloro-N-t .butyl-1, 1-dimethylsilanamine (4. Og, 16.36mmol, 68.1% purity) was dissolved in 60mL of dry THF and cooled to -70oC. 2, 3 , 4-Trimethyl-l- (t .butyl, dimethylsiloxy) cyclopentadienyl lithium was dissolved in 2|0OmL of dry THF using a 60oC heating bath. This solution was cooled to -70oC and added over 35 minutes to the silanamine solution. The mixture was allowed to warm to ambient temperature then heated to 70oC overnight. The solvents were removed under vacuum and the product extracted with 3x5OmL pentane and filtered. The solvents were removed under vacuum to give a pale yellow liquid. Yield 5.59g (93.1%). Purity according to 1H-NMR was 99%.
αH-NMR (CDC13) : δ 2.65 (s, IH) , 1.89 (s, 3H) , 1.75 (s, 3H) , 1.68 (s, 3H) , 1.15 (s, 9H) , 0.95 (s, 9H) , 0.13 (s, 3H) , 0.11 (s, 3H) , 0.08 (s, 3H) , -0.06 (s, 3H) . The GC/MS analysis showed the decomposition pattern of the parent ion of the title compound, C20H41NOSi2 corresponding to molecular weight M+=367.72 g rnol"1.
(d) Synthesis of N- (t. butyl) -N- (1- (2- ( (1-t .butyl) -1, 1- dimethylsilyloxy) -3,4, 5-trimethylcyclopentadienyl) -1,1- dimethylsilyl) -amine dilithium
3.2 mL (5.5 mmol) of 1.7M methyl lithium was added using a syringe at -30°C over 7 minutes into a solution of l.Og (2.7 mmol) of ( (2-tert-butyldimethylsiloxy) -3 , 4 , 5- trimethylcyclopentadienyl) -dimethylsilyl) tert- butylamine dissolved in 75 L of heptane to give a pale
yellow precipitate. The mixture was warmed to ambient temperature and stirred overnight. All solvents were removed in a vacuum and the dilithium salt isolated in a quantitative yield. The crude product obtained was used in a subsequent reaction without further purification. 1H-NMR analysis showed multiple peaks at δ 0-2.6 ppm which were not identified. The air sensitive product decomposed during EIMS analysis
(e) Synthesis of N- ( ert-butyl) -N- (1- (2- ( (1- tert- butyl) -1, 1-dimethylsilyloxy) -3,4, 5-trimethylcyclopenta- dienyl) -1, 1-dimethylsilyl) amine titanium dichloride
1.04g (2.7 mmol) of N- ( tert-butyl) -N- (1- (2- ( (1- tert- butyl) -1, 1-dimethylsilyloxy) -3 , 4, 5-trimethylcyclopenta- dienyl) -1, 1-dimethylsilyl) amine dilithium salt dissolved in 30 mL of THF was added into a solution of 1.02g (2.7 mmol) of TiCl3(THF)3 dissolved in 100 mL of THF at 0°C over 10 minutes to give a dark solution which was stirred at ambient temperature for 3.5 hours. 0.65g (2.3 mmol) of PbCl2 was added in one portion to give a red mixture which was stirred overnight. Solvents were removed in vacuum and the product extracted with 30 mL of toluene and filtrated. The precipitate was washed with 2x30 ml more toluene and the solvents removed in vacuum. The product was purified by recrystallisation from 50 mL of heptane at -30°C. Yield 1. lg (84.1%) of brown-red solid. The compound decomposed during EIMS analysis.
XH-NMR (CDC13) : δ 2.35 (s, 3H) , 2.28 (s, 3H) , 2.01 (a, 3H) , 1.47 (s, 9H) , 1.24 (s, 9H) , 0.94 (s, 3H) , 0.87 (s, 3H) , 0.30 (m, 3H) , 0.25 (m, 3H) .
Example 2
Ethylene polymerization
Ethylene was polymerized using the procatalyst of
Example 1 and MAO or HIBAO in an Al:Ti molar ratio of 1000:1. The polymerization medium was pentane and polymerization was effected for 30 minutes with no hydrogen present and a 10 bar ethylene partial pressure. Further details of the polymerization procedure and the polymer products are set out in Table 1 below:
CO c
m
C m r