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  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
  • C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
  • C09J123/10—Homopolymers or copolymers of propene
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  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
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  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F110/02—Ethene
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  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F110/04—Monomers containing three or four carbon atoms
  • C08F110/06—Propene
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  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F110/14—Monomers containing five or more carbon atoms
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  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F132/00—Homopolymers of cyclic compounds containing no unsaturated aliphatic radicals in a side chain, and having one or more carbon-to-carbon double bonds in a carbocyclic ring system
  • C08F132/02—Homopolymers of cyclic compounds containing no unsaturated aliphatic radicals in a side chain, and having one or more carbon-to-carbon double bonds in a carbocyclic ring system having no condensed rings
  • C08F132/04—Homopolymers of cyclic compounds containing no unsaturated aliphatic radicals in a side chain, and having one or more carbon-to-carbon double bonds in a carbocyclic ring system having no condensed rings having one carbon-to-carbon double bond
• • C—CHEMISTRY; METALLURGY
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  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F210/04—Monomers containing three or four carbon atoms
  • C08F210/06—Propene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F210/14—Monomers containing five or more carbon atoms
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  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
  • C08F210/16—Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
  • C08F4/65908—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
  • C08F4/65912—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an organoaluminium compound
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F4/00—Polymerisation catalysts
  • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
  • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
  • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
  • C08F4/62—Refractory metals or compounds thereof
  • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
  • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
  • C08F4/6592—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring
  • C08F4/65922—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring containing at least two cyclopentadienyl rings, fused or not
  • C08F4/65925—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring containing at least two cyclopentadienyl rings, fused or not two cyclopentadienyl rings being mutually non-bridged

Definitions

• This invention relates to complex compounds of tris(pentafluorophenyl)borane and to mixtures containing the borane complexes and an organometallic complex that are useful as catalysts for polymerization and copolymerization of olefins and to polymeric products prepared using these catalysts.
• Ziegler-Natta type catalyst systems Use of soluble Ziegler-Natta type catalyst systems in the polymerization of olefins, in particular polymerization of ethylene to polyethylene is known in the art.
• traditional Ziegler-Natta type systems comprise a transition metal halide activated to form a catalyst species by reaction with a metal alkyl cocatalyst, particularly aluminum alkyl cocatalysts.
• metal alkyl cocatalysts are often used in large excess, see U.S. Patent No. 4,404,344. This is disadvantageous because the aluminum compounds must be removed from the resultant polymers.
• These traditional Ziegler-Natta catalysts often contain a variety of different active sites, each of which has its own rate of initiation, propagation, and termination.
• the linear polyethylene has a broad molecular weight distribution.
• Comprehensive Organometallic Chemistry Wilkinson, G., Ed.; Pergamon Press: Oxford, 1982; Vol. 3, Chapter 22.5, p 475; Transition Metals and Organometallics as Catalysts for Olefin Polymerization; Kaminsky, W. and Sinn, H., Eds.; Springer- Verlag: New York, 1988, and Transition Metal
• Tris(pentafluorophenyl)borane (C$Fs) 3 B forms 1 : 1 complexes with Lewis bases such as ether, amines, and phosphines.
• EPO 0418044 describes monocyclopentadienyl complex catalysts containing a non-coordinating, compatible anion such as More recently, homogeneous catalysts exemplified by [Cp 2 ZrMe][MeB(CeF5) 3 ] have been synthesized from the reaction of Cp 2 ZrMe 2 and (C ⁇ F 5 ) 3 B see X. Yang et al. J. Am. Chem. Soc. 1991, 113, 3623.
• the above described catalysts are sparingly soluble in toluene.
• the catalysts are even less soluble in normally liquid ⁇ -olefins such as 1-hexene or in mixtures of such olefins and non-reactive solvents, such as hexane, toluene or xylene.
• These catalysts generally separate as oils from toluene or toluene-hexane mixtures. Even though catalysis still proceeds, phase separation is undesirable for several reasons, for example contact between monomer and catalyst is les lefficient when the catalyst is only partially soluble.
• catalyzed polymerization typically takes place at different rates either in solution or at the solid-liquid interface, thus tending to lead to a broad distribution of polymer molecular weights. Furthermore, catalysf.monomer ratio in solution is generally difficult to control when the catalyst is only partially soluble.
• a soluble or molecularly dispersed catalyst typically permits more ready access of the substrate to the active sites. As a result, more efficient use of the catalyst is possible. It is also recognized that the molecular weight of a polymer is proportional to the concentration of monomer in the reaction mixture in which it is synthesized. Generally, high molecular weight is desirable in applications such as glues and adhesives, as well as in the construction of rigid objects such as gaskets, insulators and packaging materials. Catalytic polymerization of lower olefins, in particular ethylene and propylene is relatively easy.
• Amorphous atactic polypropylene has been available as a byproduct of the manufacture of crystalline, isotactic polypropylene.
• the byproduct material has a relatively low molecular weight and is easily separated from crystalline polymer by extraction with organic solvents. Because of low molecular weight, this material lacks the cohesive strength and other desirable mechanical properties that are associated with high molecular weight polypropylene.
• Atactic polypropylene was prepared by Herwig and Kaminsky ⁇ Polymer Bulletin, 1983, 9, 464-469), using a catalyst system comprising, for instance, (cyclopentadienyl) 2 Ti(CH 3 ) 2 and methylaluminoxane.
• a M n 88,000 is reported for propylene homopolymer, without further characterization.
• Canadian Patent Application No. 2,067,525 describes homopolymerization of propylene in which various fluorenyl-containing zirconium or hafnium metallocene catalysts were used. In a number of cases, the resulting polymer mixture contained large amounts of hexane- or xylene-soluble fractions.
• U. S. Patent Nos 3,954,697 and 3,923,758 describe the production of low molelcular weight amorphous homo- and co-polymers of propylene, employing a catalyst comprising titanium halides and a trialkyl aluminum species.
• the copolymers are described as pressure-sensitive adhesives and are applied to a backing by hot-melt coating.
• the addition of tackifiers to these (co)polymers is described in U. S. Patent No. 4,264,756.
• Atactic polypropylene has been prepared by the hydrogenation of poly( 1,3 -dimethyl- 1-butylene), which was prepared via the anionic homopolymerization of (E)-2-methyl-l,3-pentadiene, as described by Zhongde et al., Macromolecules, 1985, 18, 2560 - 2566.
• the polymer is described as "near- monodisperse,” t.e., having a polydispersity index approximately equal to 1.0, and clearly does not arise from homopolymerization of propylene monomer.
• WO 89/03847 describes a low molecular weight amorphous hexene-propylene copolymeric hot-melt pressure sensitive adhesive, prepared by high-temperature solution copolymerization using TiCU supported on MgCl 2 , a preactivated catalyst comprising TiCl 3 , and an aluminum alkyl co-catalyst.
• the copolymer comprises about 40 to 75 weight percent 1-hexene, preferably 55 to 65 weight percent.
• European Patent Application No. 232,201 describes the homopolymerization of propylene on MgCl 2 -supported TiCU in the presence of an aluminum alkyl, to give a low molecular weight amorphous polymer having good hot-melt PSA characteristics. Copolymerization with only ethylene is described.
• catalyst precursor complexes comprising tris(pentafluorophenyl)borane, (C ⁇ Fs) 3 B and at least one complexing compound such as water, alcohols, mercaptans, silanols, and oximes.
• These neutral complexes may be converted to acidic salts of their conjugate bases by reaction with amines.
• the neutral complexes or acidic salts are reacted with Periodic Table Group IVB organometallic compounds to form catalytically active compounds (hereinafter also referred to as catalysts) useful for polymerization of olefin monomers.
• the catalysts of the present invention are soluble in olefins to the extent of 1 x 10 "3 molar (M) or greater.
• Catalysts that can function in undiluted monomer, as distinguished from monomer dissolved in inert diluent, are desirable because the catalysts and monomers tend to produce products having higher molecular weight. Additionally, because only low levels of the catalysts are used, removal of catalyst or its components from the final, product polymer is generally not required.
• Catalysts of the present invention may be used to prepare polyolefins from olefinically unsaturated monomers having 2 to 30, preferably 5 to 10 carbon atoms.
• the resulting polymers have a weight average molecular weight of 100,000 to 5,000,000, preferably 500,000 to 3,500,000 and have a polydispersity (PD) of molecular weights ⁇ 3.5, preferably 1.5 to 3.
• Polymers prepared from long chain ⁇ -olefins having high molecular weight and low polydispersity are not previously described.
• catalysts of the present invention surprisingly may be used to prepare amorphous, rubbery polypropylene homopolymers and copolymers having weight average molecular weights of from about 100,000 to about 5,000,000, preferably from about 200,000 to 1,000,000.
• weight average molecular weights of from about 100,000 to about 5,000,000, preferably from about 200,000 to 1,000,000.
• Such atatic polypropylene homopolymers and copolymers have not previously been described.
• Suitable olefinically unsaturated monomers that may be polymerized using the catalysts of the present invention include, but are not limited to, linear- and branched ⁇ -olefins, cyclic olefins, olefins containing an aromatic group such as phenyl, olefins containing silicon and boron, and diolefins. Mixtures of these of monomers, as well as mixtures containing olefins and diolefins may be copolymerized.
• Preferred unsaturated monomers include linear ⁇ -olefins having the general formula C PainH2n, where n is 3 to 10.
• a feature of the present invention is the incorporation of anions of the type YX-B(C ⁇ F5) 3 " into novel complex salts of Group IVB transition metals (titanium, zirconium, and hafnium), to produce highly active catalysts capable of polymerizing longer chain poly- ⁇ -olefins to yield products having very high molecular weights and a narrow polydispersity index. Furthermore, preparation of these salts are described, and such salts can either contain or are essentially free of Lewis bases.
• An additional feature of this invention is the incorporation of flat carbocyclic ligands into these novel complex salts, to produce olefin polymers of exceptionally high molecular weight.
• Cp means a carbocyclic ligand, such as cyclopentadienyl, indenyl or fluorenyl;
• Me means a methyl group
• Et means an ethyl group
• Bu means a butyl group
• Ph means a phenyl group
• hydrocarbyl is used in its usual sense to mean a group containing hydrogen and carbon atoms, such as alkyl, alkenyl, aryl, cycloalkyl, cycloalkenyl, alkaryl, arylalkyl, and the like;
• Group rVA and Group IVB are the Periodic Table CAS version designations.
• the compound (C ⁇ Fj) B tris(pentafluorophenyl)borane (also referred to as tris(pentafluorophenyl)boron), forms Lewis base complexes with a wide variety of alcohols, mercaptans, silanols, and oximes.
• These borane complexes are catalyst precursors that when combined with Group IVB organometallic compounds produce catalysts useful for polymerization of olefins, such that the polymers have high molecular weights and low polydispersities, that is a narrow molecular weight distributions.
• Lewis base complexes of (C ⁇ Fs) 3 B bearing at least one acidic hydrogen atom on the boron-bound heteroatom are useful for preparing catalysts. These compounds can be represented by the general formula: (C6F 5 ) 3 B (YXH)q wherein X, Y and q are as described below and the valence of X is completed with hydrogen atoms where necessary to provide a neutral compound.
• reaction scheme illustrates how neutral Lewis base complexes of tris(pentafluorophenyl)borane and corresponding acidic salts may be prepared.
• the reaction scheme depicts (C 2 H S ) 3 N as a reactant to produce acidic salts.
• reaction scheme further illustrates how the neutral Lewis base complexes of tris(pentafluorophenyl)borane and the corresponding acidic salts are believed to react with Group IVB organometallic complexes to produce the catalytically active salts of this invention.
• the neutral borane complexes have the general formula
• R 1 is a hydrocarbyl group containing 1 to 500, preferably 1 to 100 carbon atoms, and may contain a divalent oxygen and further may be a halogen-containing hydrocarbyl group, for example the R 1 group can be CH 3 OC 2 H---, t-butylcyclohexyl, isopropyl, allyl, benzyl, methyl, ethyl, C ⁇ «H 37 , oligomeric poly- ⁇ -olefins (containing 2 to 100 monomeric units), or CF 3 CF 2 (C 2 F 4 ) radicalC 2 H -, where n has an average value of 3.5;
• Tris(pentafluorophenyl)borane tends to form complexes with alcohols having the general formula R'OH.
• treatment of (C 6 F «.) 3 B with methanol liquid or vapor produces the bis(solvate) (C 6 F 5 ) 3 B-2MeOH.
• No significant amount of methanol can be removed by pumping at room temperature.
• This compound can be converted to by treatment with one equivalent of (C 6 F 5 ) 3 B.
• the 1 : 1 complex (C 6 F5) 3 B-MeOH may also be prepared by reacting (C ⁇ Fj) 3 B with one equivalent of methanol. Isopropanol forms a bis(solvate) as well but one equivalent of alcohol is removed under vacuum at room temperature.
• Tris(pentafluorophenyl)boron complexes of less volatile alcohols can be prepared by combining one equivalent each of an alcohol and (C_Js) 3 B in a suitable, nonreactive solvent such as chloroform or toluene, followed by evaporation of the solvent.
• a suitable, nonreactive solvent such as chloroform or toluene
• Suitable alcohols contain a wide variety of aliphatic or aromatic groups including but not limited to linear (stearyl alcohol), cyclic (t- butylcyclohexanol), branched (isopropanol), unsaturated (allyl alcohol), aromatic (benzyl alcohol), optically active (menthol), oxygen-substituted (MeOC 2 H-.OH), oligomeric (poly-1-hexene alcohol), and halogen-substituted [CF 3 CF 2 (C 2 F 4 ) ceremoniC 2 H 4 OH], where n has an average value of 3.5.
• Suitable alcohols generally have pKa values between -2 and -4.
• 2,2,2-trifluoroethanol and phenol do not form isorable complexes. Formation of a stable complex is readily ascertained by boron nuclear magnetic resonance ( ⁇ B NMR) spectroscopy.
• the (C 6 F 5 ) 3 B complexes of this invention have chemical shifts between -5 and + 15 ppm (relative to external BF 3 .OEt 2 ) compared with +60 ppm for the starting material
• silanols include but are not limited to (t-C-JI ⁇ Me ⁇ SiOH and (Me 3 SiO) 3 SiOH.
• Higher mercaptans having low vapor pressures are preferred in catalyst applications such that the polymers produced do not have an objectionable odor.
• An example of a mercaptan useful in the present invention is octadecyl mercaptan.
• Examples of oximes include acetone oxime and cyclohexanone oxime.
• the heteroatom-bound protons in Lewis base complexes such as (C 6 F 5 ) 3 B'R 1 OH and (C 6 F S ) 3 B-R 1 SH are acidic and can be removed by treatment with bases such as primary, secondary, or tertiary amines.
• bases such as primary, secondary, or tertiary amines.
• reaction of (C 2 H 5 ) 3 N with (C 6 F5) 3 B-3H 2 O or (C 6 F 5 ) 3 B-2CH 3 OH produces the acidic salts [(C 2 Hj) 3 NH] + [(C 6 F5) 3 BOH] ' and [Et3NH] + [(C6F5)3BOCH 3 ] ] ' respectively.
• Preferred bases are triethylamine, tributylamine and N,N-dimethylaniline.
• Catalysts useful for polymerization of olefinic hydrocarbons may be prepared using the precursor borane complexes and hydrocarbylcyclopentadienyl metal complexes having the general formula: wherein M is titanium, zirconium or hafnium; p is 1 or 2 Cp is a cyclopentadienyl ligand, wherein each carbon atom in the ring may be, independently, substituted with a radical selected from the group consisting of hydrocarbyl radicals, hydrocarbyl- substituted metalloid radicals wherein the metalloid is selected from Group IVA of the Periodic Table of the elements wherein the hydrocarbyl and substituted-hydrocarbyl radicals contain 1 to 20 carbon atoms and can include straight and branched alkyl groups, cyclic hydrocarbon groups, alkyl-substituted cyclic hydrocarbon groups, aromatic groups or alkyl-substituted aromatic groups; one or two pairs of adjacent hydrogen atoms of the cyclopentadie
• Cp examples include but are not limited to cyclopentadienyl, indenyl, fluorenyl, bis(octahydrofluorenyl), l,2-bis(l-indenyl)ethane, 1,2- bis(tetrahydroindenyl)ethane, isopropyl(cyclopentadienyl-l-fluorenyl), 1 ,2-bis(9- fluorenyl)ethane, and l,3-bis(9-fluorenyl)propane.
• Chiral metallocenes are also suitable and useful when a stereoregular polymer is desired.
• General structures of cyclopentadienyl, indenyl and fluorenyl ligands, respectively are represented below.
• the organometallic complex (Cp)pM(R 4 ) - p , is believed to react with acid salts of the anions, such as (C 6 F J ) 3 BOR 1 -, (C 6 F 5 ) 3 B OSi(R 2 ) 3 - or (containing at least one acid proton in the cationic portion of the salt) to form byproducts and catalytically active salts containing (Cp)pM(R 4 ) 3 . p + .
• acid salts of the anions such as (C 6 F J ) 3 BOR 1 -, (C 6 F 5 ) 3 B OSi(R 2 ) 3 - or (containing at least one acid proton in the cationic portion of the salt) to form byproducts and catalytically active salts containing (Cp)pM(R 4 ) 3 . p + .
• acid salts of the anions such as (C 6 F J ) 3 BOR 1 -, (C 6 F 5 ) 3
• the need for an acidic salt can be by-passed in the direct reaction of the metal complexes with neutral complexes of tris(pentafluorophenyl)borane with water, alcohols, mercaptans, silanols or oximes.
• the metal complexes with neutral complexes of tris(pentafluorophenyl)borane with water, alcohols, mercaptans, silanols or oximes.
• catalysts prepared by either route can be used as catalysts for the polymerization of olefins.
• catalysts prepared according to Reaction Scheme II can be obtained free of extraneous Lewis base byproduct such as triethylamine (obtained in Scheme I).
• Materials described in this invention are useful for polymerization of olefins such as ethylene and propylene and in particular higher olefins, for example, 1-hexene or 1-octene.
• Polyolefins having high weight average molecular weights may be prepared by treating undiluted olefins with a catalytically effective amount of a catalyst of the present invention.
• the polyolefins may be diluted with an inert diluent, such as toluene or hexane.
• Catalysts of the present invention may be used to prepare polyolefins from olefinically unsaturated monomers having from 2 to 30, preferably 5 to 10 carbon atoms.
• the resulting polymers have a weight average molecular weight of 100,000 to 5,000,000, preferably 500,000 to 3,500,000 and have a polydispersity (PD) of molecular weights ⁇ 3.5, preferably 1.5 to 3.
• Polymers prepared from longer chain olefins, for example, (n > 5), having high molecular weight and low polydispersity have not been previously described.
• Amorphous atactic propylene homopolymers and copolymers prepared according to the present invention have weight average molecular weights in the range of from about 100,000 to about 5,000,000, preferably from about 200,000 to about 1,000,000, as determined by gel permeation chromatography (GPC).
• GPC gel permeation chromatography
• "atactic" or "atacticity" of polypropylene (co)polymers of the present invention is defined as no observable crystallinity using Wide Angle X- Ray Scattering (WAXS) methods and no observable crystalline melting peak using Differential Scanning Calorimetry (DSC), which means the level of crystallinity in this material is presently below the limits of detection, for example, less than 1%.
• WAXS Wide Angle X- Ray Scattering
• DSC Differential Scanning Calorimetry
• atactic polypropylene typically exhibits approximately 6% ⁇ 3% of the (mmmm) pentad as measured using 13 C NMR (A. E. Tonelli, NMR Interpretation of Polymer Structure, VCH, New York (1989)). NMR results of 6% ⁇ 3% of the (mmmm) are consistent with a completely random distribution of propylene monomer orientations.
• Olefinically unsaturated monomers that may be polymerized using the catalysts of the present invention include, but are not limited to, linear- and branched ⁇ -olefins, cyclic olefins, olefins containing an aromatic group such as phenyl, olefins containing silicon and boron, and diolefins. Mixtures of these monomers, as well as mixtures containing olefins and diolefins may be copolymerized.
• Ring substitution on the Cp ligand in the catalysts of the present invention can lead to reduced polymer molecular weight and activity. This is illustrated in Table 1. Reduction of polymer molecular weight is generally undesirable in many applications since it is associated with loss of polymer cohesive strength. For example, decreases in molecular weight associated with the Me 3 Si group has not been described before. It is surprising because catalysts prepared from (MesSiCp ⁇ ZrMe ⁇ and methyl aluminoxane tend to produce higher molecular weight polyhexene than does unsubstituted Cp 2 ZrMe 2 .
• An advantage of the present invention is the permissible introduction of solubilizing groups that enhance solubility of catalyst salts in the olefinic monomer or solution of monomer and solvent into the anion rather than the cation that contains the active catalytic site.
• the solubilizing groups are spatially removed from the active site, and therefore do not interfere with polymerization and thus produce polymers of high molecular weight.
• the catalyst [(indenyl)2ZrMe)][(C6F5) 3 B-OCi8H 37 ], in which the anion contains the solubilizing octadecyl group that was introduced via of the alcohol Complex is soluble to the extent of about 10 *3 M in 80:1 (v/v) 1-hexene-toluene.
• polyhexene alcohol having an average degree of polymerization of 5.9 and bearing a terminal CH 2 OH group yielded a solution as concentrated as 10 "3 M in 40: 1 hexene-hexane.
• the structure of the solubilizing group can be varied so as to produce good catalyst solubility in a monomer of choice by suitably modifying the structure of R ! OH in
• the anions of the present invention provide catalysts that produce higher molecular weight polyolefins than superficially related catalysts, even at equivalent monomer: catalyst ratios.
• organometallic compounds are reportedly useful in the preparation of catalysts, there appears to be no correlation between the structure of the ligand(s) in the organometallic portion of the catalyst and the molecular weights of polymers of higher olefins (C5 and greater) produced with such catalysts. As a result, it is not readily apparent which organometallic compounds may be used to prepare high molecular weight polymers.
• organometallic compounds may be used to prepare high molecular weight polymers.
• the soluble, homogeneous olefin polymerization catalysts described by U.S. Patent No. 4,404,344 (Kaminsky et al.) when used to prepare poly(hexene) produces oligomers having molecular weights less than 5,000.
• Amorphous atactic polypropylene and its copolymers find utility as pressure-sensitive adhesives, as vibration damping materials, as elastomers or elastic materials, as impact-modifiers for thermoplastic materials, or as modifiers for asphalt and the like.
• Other uses include, for example packaging materials, such as cling films.
• Wide angle x-ray scattering (WAXS) data were obtained employing Cu K ⁇ radiation and Laue patterns obtained in transmission mode.
• Differential Scanning Calorimetry (DSC) was carried out using a Perkin Elmer System Seven instrument at a scan rate of 20°C min '1 with nitrogen surrounding the sample.
• Materials whose weight average molecular weight exceeded 10 6 were characterized by low angle laser light scattering techniques as is known to those skilled in this art. All starting materials and solvents are commerical available or known in the literature, unless otherwise stated or apparent. All commercially available materials and solvents are available from Aldrich Chemical Co., unless otherwise noted.
• Adhesive tape properties were measured for Examples 41-49 using a 180 degree peel test and a shear hang test.
• the peel test consisted of rolling down the tape sample onto a glass surface using two passes of a 2 kg. roller. The tape was then peeled at a 180 degree angle at a rate of 30 cm/minute. The reported values are in ounces per inch of width.
• the shear hang test was run at room temperature and consisted of rolling down a 2.54 cm x 2.54 cm section of the tape onto a clean glass substrate. A 1 kg. weight was then hung from the sample, and the time for the tape to detach from the glass substrate was reported. Shear at elevated temperatures can also be done. For Examples 42 and 43, the shear hang test was run at 70 °C using a 1.27 cm x 2.54 cm sample and a 500 grams hanging weight. Time to failure was reported.
• Tris(pentafluorophenyl)borane was prepared by the reaction of C ⁇ FsLi with BC1 3 in hexane at temperatures below -50°C according to the procedure described in Massey et al. J. Organomet. Chem. 1964, 2, 245.
• a 0.87 gram was placed in one leg of a reactor consisting of an inverted U-tube, closed at both ends and fitted with a stopcock and O-ring joint so that the apparatus could be connected to a vacuum line.
• Example 1 and 1.024 grams (2 mmol) (CeFs ⁇ B in 10 mL dichloromethane was stirred for 15 minutes and then evaporated to dryness under vacuum. A quantitative yield of the product remained and was stored under dry nitrogen.
• Example 3 Preparation of[Et3NH][(C6F s ) 3 BOH]
• a solution of 3.6 grams (C 6 Fj) 3 B-3H 2 O as prepared in Example 1 in 20 mL toluene was treated with 0.76 gram triethylamine in 3 mL of the same solvent.
• the reaction mixture was diluted with 50 mL hexane to precipitate 2.75 gram of crude product.
• Karl Fisher analysis the crude product was determined to be a hydrate and the % H 2 O present was 0.66.
• the crude product was recrystallized by solution in a minimum amount of hot toluene, followed by cooling to -50°C. Filtration and vacuum drying yielded a material containing
• Tris(pentafluorophenyl)borane (0.51 gram, 1 mmol) and 0.44 gram (1 mmol) of CF 3 CF 2 (CF2CF 2 ) n CH2CH 2 OH (as prepared in U.S. Patent No.
• Example 16 Soluble catalyst prepared using (C6F s ) 3 B'C ⁇ s 37 OH
• (b) (n-CgH ⁇ C 5 H ) 2 HfMe2 was prepared by reacting NaC s H 5 in liquid ammonia with 1-CgHpBr to provide n-CgH ⁇ 7 C$H 5 . This was then converted by reaction with n-OH 9 Li and then HfCl to provide (n-CgH ⁇ CsH-j ⁇ HfCfe. Subsequent alkylation with methyllithium produced (n-CgH ⁇ CsH 4 ) 2 HfMe2. The monomerxatalyst ratio was 3200. The resulting polymer had an M- of 1932 as determined by NMR analysis.
• Example 18 Polymerization using oligomeric (polyhexene) alcohol A reaction like that in Example 16 was carried out using an oligomeric
• Example 19 Comparative example using background art catalyst Hexene was catalytically polymerized using [(CsHj)2HfMe][MeB(C6F5)3], similar to the Zr analogue described in Yang et al. J. Am. Chem. Soc. 1991, 113, 3623.
• Example 10 and (indenyl) 2 HfMe 2 was added with stirring to 13.4 grams of cold (0°C) dry, oxygen-free 1-hexene. After approximately 16 hours, the organic phase was removed and evaporated to give 1.2 grams of polymer having M consult of
• This example illustrates the preparation of a co-polymer of two different olefins.
• a catalyst was prepared from 0.025 mmole each (indenyl) 2 HfMe 2 and (C6F5) 3 B-C ⁇ H 3 OH as prepared in Example 7 in 0.3 mL of dry, oxygen-free toluene. The catalyst was added with stirring to a mixture of 26.8 grams of dry, oxygen-free 1-hexene and 2.6 grams of 4methyl-l-pentene that had been cooled to 0°C. After four days, the resulting rigid reaction product was dissolved in 50 mL of toluene and poured into 200 mL of methanol to precipitate the product.
• Example 25 A reaction similar to that Example 25 was carried out using less catalyst such that the monomerxatalyst ratio was 37,700: 1. Workup was accomplished by scraping the product from the reactor. From 40.2 grams of 1-hexene was obtained 9.8 grams of polymer. Light scattering analysis revealed that M w was
• Example 28 Copolymerization ofl-hexene and 1,13-tetradecadadiene This example illustrates copolymerization of an olefin and a diolefin.
• a solution containing 0.025 mmole of the catalyst as prepared as Example 24 was added with stirring to a cold (0°C) mixture of 26.8 (319 mmol) of 1-hexene and
• Example 29 Polymerization of ethylene
• a solution of 0.05 mmole of (indenyl) 2 TiMe 2 as prepared according in 0.5 mL toluene was added to 0.05 mmole of
• This example illustrates the polymerization of a cyclo-olefin.
• cyclopentene that had been cooled to 0°C was added a solution in 0.4 mL of toluene of the catalyst as prepared in Example 24.
• the reactor was maintained at this temperature and shaken occasionally. After two days, the mixture was filtered.
• the solid phase 1.4 grams, was digested with 50 mL of hot toluene to remove lower molecular weight oligomers and then filtered to provide 0.8 gram of a white, insoluble solid. It was identified by infrared spectroscopy and X-ray powder diffraction as poly(cyclopentene).
• Example 31 Polymerization of propylene using (fluorenyl) 2 ZrMe 2
• a solution of 0.05 mmole (C 6 F S ) 3 B and 0.05 mmole Exxal-20TM (a C 20 branched alcohol obtained from Exxon Co.) was prepared under N 2 in 0.5 mL toluene and added to 0.05 mmole (fluorenyl) 2 ZrMe 2 ⁇ cf.
• the mixture was rinsed into a glass pressure vessel with 2 mL toluene and the vessel was connected to a gas handling system. With stirring, propylene was introduced at 31 kPa. An exotherm and a brisk gas uptake were observed.
• Example 33 Polymerization of propylene using (9-methyf ⁇ uorenyl) 2 ZrMe 2 Propylene polymerization was carried out as described in Example 32, except that (9-methylfluorenyl) 2 ZrMe2, prepared according to Samuel et al. (see
• Example 25 was used as the metallocene portion of the catalyst. No insoluble isotactic polypropylene was obtained, and 0.5 grams soluble, atactic polypropylene was isolated without further characterization.
• Example 34 Polymerization of propylene using (2-phenylfluorenyl) 2 ZrMe
• a solution of 0.05 mmole (2-phenylfluorenyl) 2 ZrMe 2 prepared by the method described in Samuel et al.(see Example 25) in 0.6 mL toluene was added to 0.05 mmole (C 6 F 3 ) 3 B • C ⁇ gH 37 OH (Example 7) in 0.3 mL toluene.
• the mixture was diluted with 20 mL toluene and further mixed with 0.2 mL (octyl) 3 Al (Ethyl Corp.), then transferred to a glass pressure vessel connected to a gas handling system and stirred and cooled to -15°C.
• Propylene was introduced at 38.7 kPa, and the temperature rose to -3°C, and pressure was maintained by addition of propylene.
• the reaction vessel was opened to the air and the clear, homogeneous reaction mixture was treated with O.lgrams Irganox 1010TM antioxidant (Ciba-Geigy) .
• the polymeric product was precipitated with approximately 150 mL methanol, taken up in toluene containing 0.05 grams Irganox 1010TM, again precipitated with methanol, collected and dried in vacuum at 80°C for 12 hours to give 6.3 grams copolymer.
• DSC analysis indicated a T g of-35°C and no crystalline melting peak at 5°C min "1 scan rate. No crystallinity was detected by WAXS.
• a dry, nitrogen-purged 8 L autoclave was charged with 3 kg propylene and a solution of 3.6 gm tri-n-octylaluminum in 10 mL toluene.
• a catalyst solution prepared by combining 0.06 mmole each of [l,2-bis(9- fluorenyl)ethane]zirconium dimethyl and (C6Fj) 3 B»C ⁇ gH 3 OH (Example 7) in 20 mL toluene was injected. The reaction mixture was stirred for 3 hr then left to stand overnight. After venting, 1.02 kg rubbery polymer was removed from the reactor.
• Example 37 A dry, nitrogen-purged 3 L autoclave was charged with 500 gm propylene, 100 gm 1-octene and 1.5 gm tri-n-octylaluminum.
• a catalyst solution prepared by combining under nitrogen 0.03 mmole each [l,2-bis(9- fluorenyl)ethane]zirconium dimethyl and (C 6 F$) B ' C ⁇ gH 37 OH (Example 7) in 10 mL toluene, was introduced.
• the reactor was agitated under autogenous pressure for 16 hr then vented.
• the crude product was kept under vacuum for 24 hr. to remove volatiles.
• the yield was 300 gm.
• Example 39 - Copolymerization of Propylene and Ethylene
• a mixture of 500 gm propylene and 200 gm ethylene was charged into a dry, nitrogen-purged 3 L autoclave that contained 3 gm tri-n-octylaluminum.
• a catalyst solution prepared by combining 0.015 mmole each of [l,2-bis(9- fluorenyl)ethane]zirconium dimethyl and (C6Fs) 3 B»C ⁇ H 37 OH (Example 7) in 10 mL toluene, was then added to the reactor. The reactor was agitated at room temperature for 20 hr then vented. The copolymer removed from the reactor weighed 69 gm after vacuum drying.
• the adhesive raw materials comprised a base polymer, a tackifying resin, and optionally a plasticizing oil, although one or more tackifying resins and plasticizing resins can be used in making the pressure- sensitive adhesives of this invention.
• the tackifying resins used in these examples include Wingtack PlusTM, an aliphatic hydrocarbon resin available from Goodyear Chemical Co. that has a T g of 315 Kelvin; EscorezTM 1310LC, an aliphatic hydrocarbon resin available from Exxon Chemical Co.
• the plasticizing oil used was Shellflex 371TM, a naphthenic oil available from Shell Oil Co that has an effective T g of 209 Kelvin.
• Other tackifying resins and plasticizing oils may be used provided that they are compatible with the base polymer.
• the raw materials were dissolved in a 50/50 blend of toluene and heptane according to the formulations given in Table 2.
• the toluene/heptane blend comprised 65% of the weight of the adhesive solution.
• the solutions were subsequently coated onto a 40 micrometer thick biaxially- oriented polypropylene film and dried at 65 °C for 10 minutes, resulting in tape samples with an adhesive thickness between 25 and 40 micrometers, except for Example 45, which was coated at 70 micrometers.
• T g values given in Table 2 are the calculated glass transition temperatures of the adhesives. These values are arrived at using the Fox equation and the T g 's of the indivdual components. This formulation methodology is well described in the block copolymer PSA art, for example as described in U.S. Patent No. 5,019,071 or U.S. 5,300,057 to Miller et al.
• the range of useful elastomer content in the PSA's of this invention range from about 20% to 100%, while the useful range of calculated glass transition temperature values ranges from about 200 Kelvin to about 275 Kelvin, depending on the application for the PSA.
• higher Tg adhesives give tapes that have higher adhesion, while lower Tg adhesives give lower adhesion.
• the tape samples of Examples 41 to 49 were tested for peel and shear performance as previously described. In addition, Examples 42 and 43 were tested for high-temperature shear resistance. Adhesion data for these examples are summarized in Table 3.
• Thickness Glass oz./in. Time, Temperature (microns) minutes Shear, minutes
• Example 45 * The failure mode for Example 45 was between the adhesive and the backing, instead of between the adhesive and the glass substrate.
• the + sign denotes the samples were cut down after the noted time interval, that is, the samples did not fail at that time.
• the pressure-sensitive adhesives (PSA's) of Examples 41-49 demonstrate su ⁇ risingly good adhesion properties.
• High molecular weight homopolymers and copolymers of propylene have not previously been known to be suitable for use in pressure-sensitive adhesives as the main polymeric component.
• Examples 41 and 42 illustrate the typical properties for PSA's based on an atactic polypropylene homopolymer prepared as described in Example 36.
• Example 43 was prepared in the same fashion as Example 42, except that 0.25% by weight of a crosslinking material, 2-(3,4- dimethoxyphenyl)-4,6-bis(trichloromethyl)-l,3,5-triazine, was added.
• the adhesive was exposed to 350 mJ of UV radiation centered on a 330 nm wavelength in order to crosslink the polypropylene chains.
• using the crosslinking agent increased the shear resistance of the adhesive.
• Examples 45-47 illustrated the ability to make good pressure-sensitive adhesives from copolymers of propylene with other monomers. The adhesion properties can thus be manipulated by selection of the comonomer types and ratios, as well as by manipulation of the the variables of T g and percent elastomer as previously described.
• Examples 47 and 48 were prepared in an indentical fashion as Examples 41 and 42, except that the atactic polypropylene homopolymer was prepared using an alternative cocatalyst, methaluminoxane, as described in Example 40.
• the adhesion properties of PSA's made with the two atactic, high molecular weight polypropylene homopolymers made with the different cocatalysts were essentially identical.
• Example 49 illustrated the use of an alternative tackifying resin system. Adhesion properties for Example 49 were also very good.
• Example 50 - Cling Film To prepare a cling film, which can find use as a packaging film, 5 grams of the polymer from Example 36 were dissolved in a 10 grams of a 50/50 solution of toluene and heptane. The resulting solution was coated at a thickness of 25 micrometers on a 40 micrometer thick biaxially-oriented polypropylene film. The solution was dried by placing the film and solution in a forced air oven at 65 °C for 10 minutes. The resulting material had a large difference in the perceived coefficient of friction on the two different sides of the material.
• the side consisting of the biaxially-oriented polypropylene film had a low coefficient of friction, while the opposite side, consisting of the high molecular weight atactic polypropylene, had by comparison a high coefficient of friction. Further, this second side also had a significant tendency to cling to smooth surfaces, such as the opposite side of the material.
• Such films have application in the packaging industry as cling films and pallet wrapping films.

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