US20100190942A1 - Aminosilane compounds, catalyst components and catalysts for olefin polymerization, and process for production of olefin polymers with the same - Google Patents

Aminosilane compounds, catalyst components and catalysts for olefin polymerization, and process for production of olefin polymers with the same Download PDF

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US20100190942A1
US20100190942A1 US11/916,039 US91603906A US2010190942A1 US 20100190942 A1 US20100190942 A1 US 20100190942A1 US 91603906 A US91603906 A US 91603906A US 2010190942 A1 US2010190942 A1 US 2010190942A1
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bis
group
methylamino
silane
polymerization
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Motoki Hosaka
Takefumi Yano
Maki Sato
Kohei Kimura
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Toho Titanium Co Ltd
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Toho Catalyst Co Ltd
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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07F—ACYCLIC, CARBOCYCLIC OR HETEROCYCLIC COMPOUNDS CONTAINING ELEMENTS OTHER THAN CARBON, HYDROGEN, HALOGEN, OXYGEN, NITROGEN, SULFUR, SELENIUM OR TELLURIUM
    • C07F7/00—Compounds containing elements of Groups 4 or 14 of the Periodic Table
    • C07F7/02—Silicon compounds
    • C07F7/08—Compounds having one or more C—Si linkages
    • C07F7/10—Compounds having one or more C—Si linkages containing nitrogen having a Si-N linkage
    • 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
    • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • 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
    • 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

Definitions

  • the present invention proposes a novel aminosilane compound, particularly a novel organosilicon compound which does not include an Si—OR bond which was indispensable as an olefin polymerization catalyst component used in general technologies, a catalyst component and a catalyst for polymerization of olefins in which the aminosilane compound is used, and a process for producing olefin polymers using the catalyst component and the catalyst.
  • a solid catalyst component containing magnesium, titanium, an electron donor compound, and a halogen as essential components used for polymerization of olefins such as propylene has been known in the art.
  • a large number of methods for polymerizing or copolymerizing olefins in the presence of a catalyst for olefin polymerization comprising the above solid catalyst component, an organoaluminum compound, and an organosilicon compound have been proposed.
  • Patent Document 1 JP-A-57-63310
  • Patent Document 2 JP-A-57-63311
  • a catalyst comprising a combination of a magnesium compound, a titanium compound, and an organosilicon compound having a Si—O—C bond is used.
  • these methods are not necessarily satisfactory for producing highly stereoregular polymers in a high yield, improvement of these methods has been desired.
  • Patent Document 3 JP-A-63-3010 proposes a catalyst and a method for polymerizing propylene.
  • the catalyst comprises a solid catalyst component, obtained by processing a powder produced from a dialkoxy magnesium, an aromatic dicarboxylic acid diester, an aromatic hydrocarbon, and a titanium halide with heat, an organoaluminum compound, and an organosilicon compound.
  • Patent Document 4 proposes another catalyst for olefin polymerization and a method for polymerizing olefins in the presence of this catalyst.
  • the catalyst for olefin polymerization comprises a solid catalyst component prepared by causing a suspension liquid containing diethoxymagnesium and an alkylbenzene to come in contact with titanium tetrachloride, reacting the suspension liquid with phthalic acid chloride, and causing the resulting solid product to come in contact with titanium tetrachloride in the presence of an alkylbenzene, an organoaluminum compound, and an organosilicon compound.
  • the polymers produced using these catalysts are used in a variety of applications including formed products such as vehicles and household electric appliances, containers, and films. These products are manufactured by melting polymer powders produced by polymerization, pelletizing the melted polymer, and forming the pellets into products using various molds. In manufacturing formed products, particularly, large products by injection molding or the like, melted polymers are sometimes required to have high fluidity (melt flow rate: MFR).
  • a method of producing a copolymer in an amount just required for obtaining an olefin-based thermoplastic elastomer (hereinafter referred to as “TPO”) in a copolymerization reactor in a method of producing a copolymer in an amount just required for obtaining an olefin-based thermoplastic elastomer (hereinafter referred to as “TPO”) in a copolymerization reactor, and obtaining the TPO directly in the polymerization reactor without adding a separately-produced copolymer, that is, in so-called “manufacture of a reactor-made TPO by direct polymerization”, a melt flow rate of 200 or more is demanded in a homopolymerization stage in order to produce a finished product with a high melt flow rate and to ensure easy injection molding.
  • TPO olefin-based thermoplastic elastomer
  • the melt flow rate greatly depends on the molecular weight of the polymers.
  • hydrogen is generally added as a molecular weight regulator for polymers during polymerization of propylene.
  • a large quantity of hydrogen is usually added to produce low molecular weight polymers having a high melt flow rate.
  • the quantity of hydrogen which can be added is limited because pressure resistance of the reactor is limited for the sake of safety.
  • Patent Document 5 proposes a method of producing a polymer having a high melt flow rate and high stereoregularity by using a compound shown by the formula Si(OR 1 ) 3 (NR 2 R 3 ) as a catalyst component for polymerization of olefins.
  • Patent Document 1 JP-A-57-63310 (Claims)
  • Patent Document 2 JP-A-57-63311 (Claims)
  • Patent Document 3 JP-A-63-3010 (Claims)
  • Patent Document 4 JP-A-1-315406 (Claims)
  • Patent Document 5 Patent Document 5
  • Patent Document 5 WO 2004-16662 (Claims)
  • an object of the present invention is to provide an aminosilane compound, a catalyst component, and a catalyst for polymerization of olefins capable of excellently maintaining stereoregularity and yield of the polymer and capable of producing olefin polymers having a high melt flow rate with a given amount of hydrogen (excellent hydrogen response), and a method for producing an olefin polymer using the catalyst component or the catalyst.
  • the invention (1) provides an aminosilane compound represented by the following formula (1),
  • R 1 represents a linear or branched alkyl group having 3 to 5 carbon atoms or a cyclopentyl group, two R 1 s being either the same or different, and R 2 represents a methyl group or an ethyl group.
  • the present invention further provides a catalyst component for olefin polymerization represented by the following formula (2),
  • R 3 represents a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R a s which may be present being either the same or different
  • R 4 represents a hydrogen atom, a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R 4 s which may be present being either the same or different
  • R 5 represents a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R 5 s which may be present being either the same or different
  • R 4 and R 5 may bond to form a ring
  • the present invention further provides a catalyst for olefin polymerization formed from an aminosilane compound represented by the following formula (2) as an essential component,
  • R 3 represents a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R 3 s which may be present being either the same or different
  • R 4 represents a hydrogen atom, a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R 4 s which may be present being either the same or different
  • R 5 represents a linear or branched alkyl group having 1 to 20 carbon atoms, a cycloalkyl group or a derivative thereof, a vinyl group, an aryl group, or an aralkyl group, two or more R 5 s which may be present being either the same or different
  • R 4 and R 5 may bond to form a ring
  • n
  • the present invention provides a process for producing an olefin polymer, wherein polymerization of an olefin is carried out in the presence of the catalyst for olefin polymerization.
  • novel aminosilane compound and the specific aminosilane compound of the present invention when used as a catalyst component for olefin polymerization, can maintain a higher stereoregularity and yield of the polymer than commonly used catalysts, and can produce a polymer having a high melt flow rate with a small amount of added hydrogen (hereinafter referred to as “hydrogen response”). Therefore, owing to the capability of reducing the amount of hydrogen used for the polymerization and high catalyst activity, the catalyst is expected not only to produce polyolefins for common use at a low cost, but also to be useful in the manufacture of olefin polymers having high functions.
  • FIG. 1 is a flowchart showing a process for preparing the catalyst component and polymerization catalyst of the present invention.
  • novel aminosilane compound of the present invention compounds represented by the above-mentioned formula (1) can be given and as examples thereof, bis(ethylamino)dicylcopentylsilane, bis(ethylamino)diisopropylsilane, and bis(methylamino)di-t-butylsilane can be given.
  • a primary amino compound such as methylamine or ethylamine in a solvent is prepared in a flask under an inert gas atmosphere.
  • a cyclic ether, a dialkyl ether, toluene, or a mixture of these solvents can be given.
  • the solution prepared in the flask is cooled to ⁇ 50 to 10° C., and an ether solution of a commercially available Grignard reagent in an amount equimolar to the primary amino compound or a hydrocarbon solution of alkyllithium in an amount equimolar to the primary amino compound is added dropwise to the cooled primary amino compound solution using a dropping funnel while stirring.
  • a dialkoxydialkylsilane compound (hereinafter DADAS compound) is dissolved in a solvent and added to a flask equipped with a stirrer under an inert gas atmosphere. The solution is cooled to ⁇ 50 to 10° C.
  • DADAS compound a dialkoxydialkylsilane compound
  • a solvent for dissolving the DADAS compound a cyclic ether, a dialkyl ether, and toluene can be given.
  • the slurry of the primary amine metal salt prepared above is added dropwise thereto under an inert gas atmosphere.
  • the amount of the primary amine metal salt is adjusted to twice the number of moles of the DADAS compound.
  • the temperature is gradually increased and the reaction is carried out for several hours at a temperature of 40° C. or higher.
  • the generated solid component comprising a metal alkoxide is separated from the solvent by filtering under an inert gas atmosphere or by a centrifugal separation process, the solid component is washed, and the wash liquid is added to the solution portion.
  • the solvent component in the solution portion is evaporated under normal pressure or under reduced pressure in an inert gas atmosphere, and the main reaction product is purified by reduced pressure distillation.
  • hydrocarbon solvents such as cyclohexane, heptane, and hexane and a mixed solvent of the above-mentioned solvents can be used.
  • the structure of the obtained aminosilane compound can be determined by identification using a well-known analysis method.
  • a compound represented by the above-mentioned formula (2) can be used as the catalyst component for olefin polymerization of the present invention.
  • the aminosilane compound is a compound having a nitrogen atom directly bonded to a silicon atom.
  • R 3 is preferably a linear or branched alkyl group having 1 to 12 carbon atoms or a cycloalkyl group, two or more R 3 s which may be present being either the same or different;
  • R 4 is preferably a hydrogen atom; and
  • R 5 is preferably a linear or branched alkyl group having 1 to 3 carbon atoms.
  • the cycloalkyl derivative is a cycloalkyl group having a substituent and specifically, an alkyl-substituted cyclopentyl group, an alkyl-substituted cyclohexyl group, and an alkyl-substituted cycloheptyl group can be given as examples.
  • aminosilane compound shown by the above-mentioned formula (2) (alkylamino)trialkylsilane, (alkylamino)dialkylcycloalkylsilane, (alkylamino)alkyldicycloalkylsilane, (alkylamino)tricycloalkylsilane, (alkylamino)(dialkylamino)dialkylsilane, (alkylamino)(dialkylamino)dicycloalkylsilane, bis(alkylamino)dialkylsilane, bis(alkylamino)alkylcycloalkylsilane, bis(alkylamino)dicycloalkylsilane, bis(alkylamino)(dialkylamino)alkylsilane, bis(alkylamino)(dialkylamino)cycloalkylsilane, di(alkylamino)dialkylsilane, di(alkylamino)
  • bis(alkylamino)dicyclopentylsilane bis(alkylamino)diisopropylsilane, bis(alkylamino)di-t-butylsilane, bis(alkylamino)-t-butylethylsilane, bis(alkylamino)-t-butylmethylsilane, bis(alkylamino)dicyclohexylsilane, bis(alkylamino)cyclohexylmethylsilane, bis(alkylamino)bis(decahydronaphtyl)silane, bis(alkylamino)cyclopentylcyclohexylsilane, bis(perhydroisoquinolino)(alkylamino)alkylsilane, bis(perhydroquinolino)(alkylamino)alkylsilane, di(alkylamino)dicyclopentyls
  • aminosilane compound examples include tris(methylamino)methylsilane, tris(methylamino)ethylsilane, tris(methylamino)n-propylsilane, tris(methylamino)isopropylsilane, tris(methylamino)n-butylsilane, tris(methylamino)isobutylsilane, tris(methylamino)t-butylsilane, tris(methylamino)cyclopentylsilane, tris(methylamino)cyclohexylsilane, tris(methylamino)vinylsilane, tris(ethylamino)methylsilane, tris(ethylamino)ethylsilane, tris(ethylamino)n-propylsilane, tris(ethylamino)isopropylsilane, tris(ethylamino)methyls
  • the compound represented by the above-mentioned formula (2) can be easily synthesized by a known synthesis method such as a chlorine exchange method, a method using an organolithium compound, or a method using a Grignard reagent or by a combination of these methods.
  • a synthesis method of bis(alkylamino)dicyclopentylsilane among the aminosilane compounds of the present invention a reaction of dicyclopentyldialkoxysilane with twice the number of moles of a Li salt of an alkylamine or a Mg salt of an alkylamine can be given.
  • ether compounds such as THF and dialkyl ether, aromatic compounds such as toluene, saturated hydrocarbon compounds such as pentane, hexane, heptane, and cyclohexane, and a mixture of these solvents can be given.
  • R 3 is an alkylamine
  • the amount of the metal salt of a primary amine is adjusted to the number of the alkoxy group in the (alkoxy) n (alkyl) 4-n silane compound, that is, to 1 to 4 times the numbers of moles the (alkoxy) n (alkyl) 4-n silane compound.
  • the catalyst for olefin polymerization of the present invention is formed using the aminosilane compound represented by the above-mentioned formula (2) as an essential component.
  • the aminosilane compound represented by the above-mentioned formula (2) As specific examples of preferable compounds of formula (2) for forming the catalyst for olefin polymerization of the present invention, the same compounds as given in the description of formula (2) for the catalyst component for olefin polymerization can be given.
  • the catalyst for olefin polymerization of the present invention can be formed using (A) a solid catalyst component comprising magnesium, titanium, a halogen, and an electron-donor compound and (B) an organoaluminum compound represented by the following formula (3),
  • R 6 represents an alkyl group having 1 to 4 carbon atoms
  • Q represents a hydrogen atom or a halogen atom
  • p represents a real number satisfying the formula 0 ⁇ p ⁇ 3.
  • the solid catalyst component (A) (hereinafter referred to as “component (A)” from time to time), which comprises magnesium, titanium, a halogen, and an electron donor compound, can be obtained by causing (a) a magnesium compound, (b) a tetravalent titanium halogen compound, and (c) an electron donor compound to come in contact with each other.
  • a magnesium dihalide, a dialkylmagnesium, an alkylmagnesium halide, a dialkoxymagnesium, a diaryloxymagnesium, an alkoxymagnesium halide, and a fatty acid magnesium can be given.
  • a magnesium dihalide, a mixture of magnesium dihalide and dialkoxymagnesium, and a dialkoxymagnesium are preferable, and a dialkoxymagnesium is particularly preferable.
  • dimethoxymagnesium, diethoxymagnesium, dipropoxymagnesium, dibutoxymagnesium, ethoxymethoxymagnesium, ethoxypropxymagnesium, and butoxyethoxymagnesium can be given. Diethoxymagnesium is particularly preferable.
  • dialkoxymagnesium may be obtained by reacting metallic magnesium with an alcohol in the presence of a halogen-containing metal compound or the like.
  • the dialkoxymagnesium may be used alone or in combination or two or more.
  • the dialkoxymagnesium compound used is preferably in the form of granules or a powder and either amorphous or spherical in the configuration.
  • a polymer powder having a better particle shape and a narrower particle size distribution can be obtained. This improves handling operability of the produced polymer powder during the polymerization operation and eliminates problems such as clogging of the filter or the like in the polymer separation device caused by fine particles contained in produced polymer powder.
  • the spherical dialkoxymagnesium need not necessarily be completely spherical, but may be oval or potato-shaped.
  • the particles may have a ratio (L/W) of the major axis diameter (L) to the minor axis diameter (W) usually of 3 or less, preferably of 1 to 2, and more preferably of 1 to 1.5.
  • Dialkoxymagnesium with an average particle size from 1 to 200 ⁇ m can be used.
  • a more preferable average particle size is 5 to 150 ⁇ m.
  • the average particle size is usually from 1 to 100 ⁇ m, preferably from 5 to 50 ⁇ m, and more preferably from 10 to 40 ⁇ m.
  • a powder having a narrow particle size distribution with a small fine and coarse powder content is preferably used.
  • the content of particles with a diameter of 5 ⁇ m or less should be 20% or less, and preferably 10% or less.
  • the content of particles with a diameter of 100 ⁇ m or more should be 10% or less, and preferably 5% or less.
  • the particle size distribution represented by (D90/D10), wherein D90 is a particle size of 90% of the integrated particle size and D10 is a particle size of 10% of the integrated particle size is 3 or less, and preferably 2 or less.
  • the tetravalent titanium halide compound (b) (hereinafter referred to from time to time as “component (b)”) used for the preparation of the component (A) in the present invention is one or more compounds selected from the group consisting of a titanium halide or alkoxytitanium halide represented by the formula Ti(OR 7 ) n X 4-n , wherein R 7 represents an alkyl group having 1 to 4 carbon atoms, X represents a halogen atom, and n represents an integer satisfying the formula 0 ⁇ n ⁇ 4.
  • titanium tetrahalides such as titanium tetrachloride, titanium tetrabromide, and titanium tetraiodide and, as alkoxytitanium halides, methoxytitanium trichloride, ethoxytitanium trichloride, propoxytitanium trichloride, n-butoxytitanium trichloride, dimethoxytitanium dichloride, diethoxytitanium dichloride, dipropoxytitanium dichloride, di-n-butoxytitanium dichloride, trimethoxytitanium chloride, triethoxytitanium chloride, tripropoxytitanium chloride, and tri-n-butoxy titanium chloride.
  • titanium tetrahalides are preferable, with titanium tetrachloride being particularly preferable. These titanium compounds may be used either individually or in combination of two or more.
  • the electron donor compound (hereinafter referred to from time to time as “component (c)”) used for preparing the solid catalyst component (A) is an organic compound containing an oxygen atom or a nitrogen atom.
  • Alcohols, phenols, ethers, esters, ketones, acid halides, aldehydes, amines, amides, nitriles, isocyanates, and organosilicon compounds containing an Si—O—C bond or an Si—N—C bond can be given as examples.
  • alcohols such as methanol, ethanol, n-propanol, 2-ethylhexanol; phenols such as phenol and cresol; ethers such as dimethyl ether, diethyl ether, dipropyl ether, dibutyl ether, diamyl ether, diphenyl ether, 9,9-bis(methoxymethyl)fluorene, and 2-isopropyl-2isopentyl-1,3-dimethoxy propane; monocarboxylic acid esters such as methyl formate, ethyl acetate, vinyl acetate, propyl acetate, octyl acetate, cyclohexyl acetate, ethyl propionate, ethyl butylate, ethyl benzoate, propyl benzoate, butyl benzoate, octyl benzoate, cyclohexyl benzoate, phenyl benzoate,
  • the esters, particularly aromatic dicarboxylic acid diesters are preferably used.
  • Phthalic acid diesters and phthalic acid diester derivatives are ideal compounds.
  • Specific examples of the phthalic acid diester include the following compounds: dimethyl phthalate, diethyl phthalate, di-n-propyl phthalate, diisopropyl phthalate, di-n-butyl phthalate, diisobutyl phthalate, ethylmethyl phthalate, methylisopropyl phthalate, ethyl(n-propyl) phthalate, ethyl(n-butyl) phthalate, ethyl(isobutyl) phthalate, di-n-pentyl phthalate, diisopentyl phthalate, dineopentyl phthalate, dihexyl phthalate, di-n-heptyl phthalate, di-n-octyl phthalate,
  • the phthalic acid diester derivatives compounds in which one or two hydrogen atoms on the benzene ring to which the two ester groups of the phthalic diesters bond are replaced with an alkyl group having 1 to 5 carbon atoms or a halogen atom such as a chlorine atom, a bromine atom, and a fluorine atom can be given.
  • the solid catalyst component prepared by using the phthalic acid diester derivatives as an electron donor compound can particularly contribute to a melt flow rate increase with a given amount of hydrogen by increasing hydrogen response, that is, can increase the melt flow rate of polymer by using the same or a smaller amount of hydrogen during the polymerization.
  • ester compounds are preferably used in combination of two or more.
  • the esters are preferably combined so that the total carbon atom number in the alkyl group possessed by one ester may differ four or more from that possessed by another ester.
  • the aminosilane compounds shown by the formula (2) can also be used as the electron donor compound (c) (an internal donor) of the solid catalyst component (A).
  • Specific examples of the aminosilane compounds shown by the formula (2) used as the internal donor are the same as those of the compounds shown by the formula (2) used for the catalyst component for olefin polymerization.
  • the component (A) of the present invention can be preferably prepared by causing the above components (a), (b), and (c) to come in contact with each other in the presence of an aromatic hydrocarbon compound (d) (hereinafter may be simply referred to as “component (d)”).
  • aromatic hydrocarbon compounds having a boiling point of 50 to 150° C. such as toluene, xylene, ethylbenzene, cyclohexane, and cyclohexene are preferably used as the component (d).
  • aromatic hydrocarbons can be used either individually or in combination of two or more.
  • a method of preparing a suspension liquid of the component (a), the component (c), and the hydrocarbon compound (d) having a boiling point of 50 to 150° C., causing this suspension liquid to contact with a mixed solution made from the component (b) and the component (d), and reacting the mixture can be given.
  • a polysiloxane (hereinafter may be simply referred to as “component (e)”) can be preferably used to improve the stereoregularity or crystallinity of the formed polymer and to reduce the amount of fine polymer particles.
  • Polysiloxanes are polymers having a siloxane bond (—Si—O bond) in the main chain and are generally referred to as silicone oil.
  • the polysiloxanes used in the present invention are chain-structured, partially hydrogenated, cyclic or modified polysiloxanes which are liquid or viscous at normal temperatures with a viscosity at 25° C. in the range of 0.02 to 100 cm 2 /s (2 to 10,000 cSt).
  • dimethylpolysiloxane and methylphenylpolysiloxane can be given; as examples of the partially hydrogenated polysiloxane, methyl hydrogen polysiloxanes with a hydrogenation degree of 10 to 80% can be given; as examples of the cyclic polysiloxane, hexamethylcyclotrisiloxane, octamethylcyclotetrasiloxane, decamethylcyclopentanesiloxane, 2,4,6-trimethylcyclotrisiloxane, 2,4,6,8-tetramethylcyclotetrasiloxane can be given; as examples of the modified polysiloxane, higher fatty acid group-substituted dimethylsiloxane, epoxy group-substituted dimethylsiloxane, and polyoxyalkylene group-substituted dimethylsiloxane can be given. Of these, decamethylcyclopentas
  • the component (A) in the present invention is prepared by causing the above components (a), (b), and (c), and, as required, the component (d) or component (e) to come in contact with each other.
  • the method of preparing the component (A) will now be described in detail.
  • One specific example of the method for preparing the component (A) comprises suspending the magnesium compound (a) in an alcohol, a halogenated hydrocarbon solvent, the tetravalent titanium halide (b), or the hydrocarbon compound (d), and causing the electron donor compound (c) such as a phthalic acid diester and/or the tetravalent titanium halide (b) to come in contact with the suspension.
  • the component (A) in the form of spherical particles with a sharp particle size distribution can be obtained by using a spherical magnesium compound.
  • a component (A) in the form of spherical particles with a sharp particle size distribution can also be obtained without using a spherical magnesium compound If particles are formed by a spray dry method in which a solution or a suspension liquid is sprayed and dried using a sprayer, for example.
  • the contact temperature which is a temperature when these components are caused to come into contact with each other, may be either the same as or different from the reaction temperature.
  • the components When the components are caused to come into contact with each other by stirring for preparing the mixture or are dispersed or suspended for a denaturing treatment, the components may be stirred at a comparatively low temperature of around room temperature. A temperature in a range from 40 to 130° C. is preferable for obtaining the product by reaction after contact. The reaction does not sufficiently proceed at a reaction temperature below 40° C., resulting in a solid catalyst component with inadequate properties. On the other hand, control of the reaction becomes difficult at a temperature above 130° C. due to vaporization of the solvent and the like.
  • the reaction time is one minute or more, preferably ten minutes or more, and still more preferably 30 minutes or more.
  • a process comprising suspending the component (a) in the component (d), causing the resulting suspension to come in contact with the component (b), then the component (c) and component (d), and causing these components to react and a process comprising suspending the component (a) in the component (d), causing the resulting suspension liquid to come in contact with the component (c), then the component (b), and causing these components to react
  • the component (A) thus prepared may be caused to come in contact with the component (b) or the components (b) and (c) once more or two or more times to improve the performance of the ultimate solid catalyst component.
  • This contacting step is preferably carried out in the presence of the hydrocarbons (d).
  • a method of preparing a suspension liquid of the component (a), the component (c), and the hydrocarbon compound (d) having a boiling point of 50 to 150° C., causing this suspension liquid to contact with a mixed solution made from the component (b) and the component (d), and reacting the mixture can be given.
  • a suspension is prepared from the above component (a), component (c), and a hydrocarbon compound (d) having a boiling point of 50 to 150° C.
  • a mixed solution is prepared from the above component (c) and the hydrocarbon compound (d) having a boiling point of 50 to 150° C.
  • the above-described suspension liquid is added to this solution.
  • the resulting mixture is heated and reacted (a primary reaction). After the reaction, the solid product is washed with a hydrocarbon compound which is liquid at normal temperatures to obtain a solid product.
  • the temperature is raised to react the mixture (a secondary reaction), and after the reaction, the reaction mixture is washed with a hydrocarbon compound which is liquid at normal temperatures one to ten times to obtain the component (A).
  • a particularly preferable process for preparing the solid catalyst component (A) comprises suspending the dialkoxymagnesium compound (a) in the hydrocarbon compound (d) having a boiling point in the range of 50 to 150° C., causing the tetravalent titanium halide (b) to contact the suspension liquid, and reacting the mixture.
  • one or more electron donor compounds (c) such as phthalic acid diester are caused to come in contact with the suspension liquid at a temperature from ⁇ 20 to 130° C., either before or after the tetravalent titanium halide compound (b) is contacted, then optionally, the component (e) is contacted and reacted to obtain a solid product (1).
  • the tetravalent titanium halide (b) is again caused to come contact and react with the solid product (1) in the presence of the hydrocarbon compound at a temperature of ⁇ 20 to 100° C. to obtain a solid reaction product (2).
  • the intermediate washing and the reaction may be further repeated several times.
  • the solid product (2) is washed with a liquid hydrocarbon compound by decantation at normal temperature to obtain the solid catalyst component (A).
  • the ratio of the components used for preparing the solid catalyst component (A) cannot be defined unconditionally, because such a ratio varies according to the method of preparation employed.
  • the tetravalent titanium halide (b) is used in an amount from 0.5 to 100 mol, preferably from 0.5 to 50 mol, still more preferably from 1 to 10 mol
  • the electron donor compound (c) is used in an amount from 0.01 to 10 mol, preferably from 0.01 to 1 mol, and still more preferably from 0.02 to 0.6 mol
  • the hydrocarbon compound (d) is used in an amount from 0.001 to 500 mol, preferably from 0.001 to 100 mol, and still more preferably from 0.005 to 10 mol
  • the polysiloxane (e) is used in an amount of from 0.01 to 100 g, preferably from 0.05 to 80 g, and still more preferably from 1 to 50 g, for one mol of the magnesium compound (a).
  • the content of titanium is from 0.5 to 8.0 wt %, preferably from 1.0 to 8.0 wt %, and still more preferably from 2.0 to 8.0 wt %;
  • the content of magnesium is from 10 to 70 wt %, preferably from 10 to 50 wt %, more preferably from 15 to 40 wt %, and particularly preferably from 15 to 25 wt %;
  • the content of halogen atoms is from 20 to 90 wt %, preferably from 30 to 85 wt %, more preferably from 40 to 80 wt %, and particularly preferably from 45 to 75 wt %;
  • the total amount of electron donor compounds is from 0.5 to 30 wt %, preferably from 1 to 25 wt %, and particularly preferably from 2 to 20 wt %.
  • R 6 is preferably an ethyl group or an isobutyl group
  • Q is preferably a hydrogen atom, a chlorine atom, or a bromine atom
  • p is preferably 2 or 3, and particularly preferably 3.
  • organoaluminum compound (B) triethylaluminum, diethylaluminum chloride, triisobutylaluminum, diethylaluminum bromide, and diethylaluminum hydride can be given. These compounds may be used either individually or in combination of two or more. Triethylaluminum and triisobutylaluminum are preferably used.
  • the compounds represented by the above formula (2) can be given as the aminosilane compound (C) (hereinafter may be referred to from time to time as “component (C)”) which can be used for preparing the catalyst for olefin polymerization of the present invention.
  • component (C) the aminosilane compound which can be used for preparing the catalyst for olefin polymerization of the present invention.
  • Specific examples of the compounds shown by the formula (2) used as the component (C) are the same as those of the compounds shown by the formula (2) used for the catalyst component for olefin polymerization.
  • component (D) an organosilicon compound other than the above-described aminosilane compound (hereinafter may be simply referred to as “component (D)”) may be used for preparing the catalyst for olefin polymerization of the present invention.
  • organosilicon compound (D) one or more organosilicon compounds shown by the formula R 8 q Si(OR 9 ) 4-q , wherein R 8 represents a hydrogen atom, an alkyl group, a cycloalkyl group, a phenyl group, a vinyl group, an allyl group, an aralkyl group, an alkylamino group, a cycloalkylamino group, or a polycyclic amino group having 1 to 20 carbon atoms, two or more R 8 s which may be present being either the same or different, R 9 represents a linear or branched alkyl group, a cycloalkyl group, a vinyl group, an allyl group, or an aralkyl group having 1 to 20 carbon atoms, two or more R 9 s which may be present being either the same or different, and q is an integer of 1 to 3.
  • alkylalkoxysilane, alkyl(cycloalkyl)alkoxysilane, cycloalkylalkoxysilane, phenylalkoxysilane, alkyl(phenyl)alkoxysilane, alkyl(alkylamino)alkoxysilane, alkylaminoalkoxysilane, cycloalkyl(alkylamino)alkoxysilane, alkyl(cycloalkylamino)alkoxysilane, polycyclic aminoalkoxysilane, and alkyl(polycyclic amino)alkoxysilane can be given.
  • organosilicon compound (D) that can be preferably used, di-n-propyldimethoxysilane, diisopropyldimethoxysilane, di-n-butyldimethoxysilane, di-n-butyldiethoxysilane, t-butyl(methyl)dimethoxysilane, t-butyl(ethyl)dimethoxysilane, dicyclohexyldimethoxysilane, cyclohexyl(methyl)dimethoxysilane, dicyclopentyldimethoxysilane, cyclopentyl(methyl)diethoxysilane, cyclopentyl(ethyl)dimethoxysilane, cyclopentyl(cyclohexyl)dimethoxysilane, 3-methylcyclohexyl(cyclopentyl)dimethoxysilane, 4-methylcyclohexyl(cyclopentyl)d
  • Olefins are polymerized or copolymerized by random or block copolymerization in the presence of the catalyst for olefin polymerization of the present invention.
  • the olefins such as ethylene, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, and vinyl cyclohexane can be used either individually or in combination of two or more. Of these, ethylene, propylene, and 1-butene can be suitably used.
  • a particularly preferable olefin is propylene.
  • Propylene may be copolymerized with other olefins
  • ethylene, 1-butene, 1-pentene, 4-methyl-1-pentene, vinyl cyclohexane, and the like can be used either individually or in combination of two or more. Of these, ethylene and 1-butene can be suitably used.
  • random copolymerization of polymerizing propylene as a copolymer with a small amount of ethylene in one step, and propylene-ethylene block copolymerization of polymerizing only propylene in a first step (first polymerization vessel) and copolymerizing propylene and ethylene in a second step (second polymerization vessel) are typical methods.
  • the catalyst of the present invention comprising the component (A), component (B), and component (C) is effective in both the random copolymerization and block copolymerization for improving the catalytic activity, stereoregularity, and/or hydrogen response, copolymerization performance, and properties of resulting copolymers.
  • the above-described component (D) may be used.
  • the components (C) and (D) may be used either as a mixture or separately in a multiple stage polymerization vessel of the block copolymerization.
  • a known electron donor compound such as an alcohol, oxygen gas, or a ketone may be added to the polymerization reaction system in order to prevent formation of gel in the finished product, particularly when shifting from homopolymerization of propylene to the block copolymerization.
  • the alcohol ethyl alcohol and isopropyl alcohol can be given. These alcohols are used in an amount of 0.01 to 10 mol, and preferably 0.1 to 2 mol, for one mol of the component (B).
  • the ratio of each component used is not specifically limited inasmuch as such a ratio does not influence the effect of the present invention.
  • the component (B) is used in an amount of 1 to 2000 mol, and preferably 50 to 1000 mol, per one mol of titanium atom in the component (A).
  • the component (C) is used in an amount of 0.002 to 10 mol, preferably 0.01 to 2 mol, and particularly preferably 0.1 to 0.5 mol per one mol of the component (B).
  • the amount is 0.002 to 10 mol, preferably 0.01 to 2 mol, and particularly preferably 0.01 to 0.5 mol, per one mol of the component (B), and the component (C) is used in the amount of 0.001 to 10 mol, preferably 0.01 to 10 mol, and particularly preferably 0.01 to 2 mol, per one mol of the component (C).
  • organoaluminum compound (B) is added to the polymerization system, then cause the aminosilane compound (C) or a mixture of the components (C) and (D) to contact the organoaluminum compound (B), or cause the component (C) and component (D) in an optional order to contact the organoaluminum compound (B), and cause the solid catalyst component (A) to contact the resulting mixture.
  • a method of forming a catalyst by adding the organoaluminum compound (B) to the polymerization system, separately causing the component (A) to contact the component (C) or the components (C) and (D), and feeding the contacted component (A) and component (C) or the components (C) and (D) to the polymerization system is also a preferable embodiment. It is possible to further improve the hydrogen response of the catalyst and crystalline properties of the resulting polymer by using a previously contacted mixture of the component (A) with the component (B) or the component (C), and the component (D).
  • polymerization can be carried out either in the presence or in the absence of an organic solvent.
  • Olefin monomers such as propylene may be used either in a gaseous state or in a liquid state.
  • the polymerization reaction is preferably carried out at a temperature of 200° C. or less, and preferably at 150° C. or less, under a pressure of 10 MPa or less, and preferably 6 MPa or less.
  • Either a continuous polymerization system or a batch polymerization system may be used for the polymerization reaction.
  • the polymerization can be completed either in one step or in two or more steps.
  • main polymerization In polymerizing olefins using the catalyst formed from the component (A), component (B), and component (C) (hereinafter may be referred to from time to time as “main polymerization”), it is desirable to preliminarily polymerize the olefins prior to the main polymerization to further improve the catalyst activity, stereoregularity, properties of resulting polymer particles, and the like.
  • monomers such as styrene can be used in the preliminary polymerization.
  • the component (A) after causing the component (A) to contact the component (B) and/or the component (C) in the presence of olefins to preliminarily polymerize 0.1 to 100 g of the polyolefins for 1 g of the component (A), the component (B) and/or the component (C) are further caused to contact to form the catalyst.
  • the component (D) it is possible to cause the component (A) to contact the components (B) and (D) in the presence of olefins during the preliminary polymerization and to use the component (C) during the main polymerization.
  • the order of contact of the components and monomers in carrying out the preliminary polymerization is optional, it is desirable to first add the component (B) to the preliminary polymerization system in an inert gas or olefin gas atmosphere such as propylene, cause the component (C) and/or the component (D) to come in contact with the component (A), and then cause an olefin such as propylene and/or one or more other olefins to come in contact with the mixture.
  • the preliminary polymerization temperature is from ⁇ 10 to 70° C., and preferably from ⁇ 5 to 50° C.
  • the polymerization of olefins in the presence of the olefin polymerization catalyst of the present invention can produce olefin polymers in a higher yield than in the polymerization using a known catalyst, while maintaining a higher stereoregularity of the polymer and improved hydrogen response.
  • the catalytic activity and stereoregularity are improved as compared with the case in which a commonly-used catalyst is used.
  • the catalyst of the present invention is used for polymerization of olefins, it has been confirmed that the hydrogen response is improved while maintaining high stereoregularity depending on the structure of the component (C).
  • the organosilicon compound of the present invention can be used as a conductor insulation film material, a surface treating agent of a printed circuit board, a photoresist raw material or intermediate material thereof, and the like.
  • a flask in which the internal atmosphere was sufficiently replaced with nitrogen gas was charged with a THF solution of ethylamine in a nitrogen stream.
  • the solution was cooled to ⁇ 10 to 0° C. and a hexane solution of commercially available butyl lithium, in an amount equimolar to ethylamine, was slowly added using a dripping funnel while stirring. After the addition, the temperature was gradually increased to 50° C. and the mixture was reacted for two hours to obtain a slurry of lithium salt of ethylamine.
  • IR Measuring device: “Avatar 360FT/IR” manufactured by Nicolet Co, NaCl sandwiching method, Measurement temperature: room temperature
  • a three-necked flask in which the internal atmosphere was sufficiently replaced with nitrogen gas was charged with 60 ml of a THF solution containing 0.04 mol of ethylamine in a nitrogen stream.
  • 30 ml of a hexane solution containing 0.04 mol of BuLi was slowly added to the ethylamine solution cooled to ⁇ 10° C. using a dripping funnel.
  • the mixture was gradually heated and reacted at 50° C. for two hours.
  • Another container of which the internal atmosphere was purged with nitrogen was charged with 60 ml of a toluene solution containing 0.02 mol of t-butylethyldimethoxysilane and cooled to ⁇ 10° C.
  • a flask in which the internal atmosphere was sufficiently replaced with nitrogen gas was charged with a THF solution of ethylamine.
  • the solution was cooled to ⁇ 10 to 0° C. and a hexane solution of commercially available butyl lithium, in an amount equimolar to ethylamine, was slowly added using a dripping funnel while stirring. After the addition, the temperature was gradually increased to 50° C. and the mixture was reacted for two hours to obtain a slurry of lithium salt of ethylamine.
  • the reaction mixture was filtered in a nitrogen atmosphere and the solid components were washed with a small amount of toluene, thereby separating a solid from liquid.
  • the solvent was evaporated from the solution and the main product of bis(ethylamino)diisopropylsilane was purified by distillation under reduced pressure. The boiling point of the compound was found to be 68° C./7 mmHg. The yield was 87.2%.
  • This product was confirmed to be bis(ethylamino)diisopropylsilane by 1 H-NMR, IR, and the elementary analysis. The elementary analysis confirmed that the compound consists of C, 59.35% (59.34%), H, 12.96% (12.95%), and N, 13.82% (13.84%), wherein the percentages of the parentheses are theoretical values.
  • the IR spectrum had absorption by N—H stretching vibration typical to a secondary amine in the neighborhood of 3400 cm ⁇ 1 .
  • the position attributable to protons obtained from the chart of 1 H-NMR spectrum and the spectrum intensities of the positions are as shown in Table 2. The results of these analyses support that the compound obtained was bis(ethylamino)diisopropylsilane. 1 H-NMR and IR were measured under the same conditions as in Example 1.
  • the experiment was carried out in the same manner as in Example 2 except for using 0.02 mol of methylamine instead of 0.04 mol of methylamine, a hexane solution containing 0.02 mol of BuLi instead of the hexane solution containing 0.04 mol of BuLi, and 0.01 mol of t-butylethyldimethoxysilane instead of 0.02 mol of t-butylethyldimethoxysilane to obtain bis(methylamino)-t-butylmethylsilane.
  • the elementary analysis confirmed that the compound consists of C, 52.30% (52.44%), H, 12.61% (12.57%), and N, 17.51% (17.47%), wherein the percentages of the parentheses are theoretical values.
  • Bis(methylamino)dicyclohexylsilane was synthesized in the same manner as in Example 2, except that dicyclohexyldimethoxysilane was used instead of t-butylethyldimethoxysilane.
  • the elementary analysis confirmed that the compound consists of C, 66.03% (66.07%), H, 11.86% (11.88%), and N, 11.00% (11.01%), wherein the percentages of the parentheses are theoretical values.
  • Bis(methylamino)cyclohexylmethylsilane was synthesized in the same manner as in Example 2, except that cyclohexylmethyldimethoxysilane was used instead of t-butylethyldimethoxysilane.
  • the elementary analysis confirmed that the compound consists of C, 57.91% (58.00%), H, 11.68% (11.90%), and N, 15.00% (15.03%), wherein the percentages of the parentheses are theoretical values.
  • Bis(ethylamino)cyclohexylcyclopentylsilane was synthesized in the same manner as in Example 2, except that ethylamine was used instead of methylamine and cyclohexylcyclopentyldimethoxysilane was used instead of t-butylethyldimethoxysilane.
  • the elementary analysis confirmed that the compound consists of C, 67.05% (67.10%), H, 12.00% (12.01%), and N, 10.23% (10.43%), wherein the percentages of the parentheses are theoretical values.
  • the suspension liquid was added to a solution of 450 ml of toluene and 300 ml of titanium tetrachloride previously filled in another 2,000 ml round bottom flask equipped with a stirrer, of which the internal atmosphere had been sufficiently replaced with nitrogen gas.
  • the suspension liquid was reacted at 5° C. for one hour.
  • the resulting reaction mixture was washed four times with 1,300 ml of toluene at 80° C. After the addition of 1,200 ml of toluene and 300 ml of titanium tetrachloride, the reaction mixture was heated to 110° C. and reacted for two hours while stirring. The intermediate washing and the secondary treatment were repeated once more. The resulting reaction mixture was washed seven times with 1,300 ml of heptane at 40° C., filtered, and dried to obtain a solid catalyst component in the form of a powder. The content of titanium in the solid component was measured and found to be 3.1 wt %.
  • the catalyst activity, bulk density (BD, g/ml), heptane insoluble components (HI, wt %), and melt flow rate according to ASTM, in terms of the melt index (MI, g-PP/10 min), of the resulting polymer were measured.
  • the results are shown in Table 4. Blanks in the Table 4 indicate that no data was acquired.
  • the catalytic activity per gram of the solid catalyst component for the amount of polymer (F) gram per one hour of the polymerization time was calculated according to the following formula:
  • Catalytic activity Produced polymer ( F )( g )/Solid catalyst component ( g )/hour
  • the melt index (MI) which indicates the melt flow rate of the polymer was determined according to the method conforming to ASTEM D1238 or JIS K7210.
  • the molecular weight distribution of polymers was evaluated by the ratio (Mw/Mn) of the weight average molecular weight (Mw) to the number average molecular weight (Mn) measured by cross fractionation chromatography (CFC) using “CFC T-150B” (manufactured by Mitsubishi Chemical Corp.) under the following conditions.
  • Example 9 The same experiment as in Example 9 was carried out, except for using bis(methylamino)-t-butylethylsilane obtained in Example 2 instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 4.
  • Example 9 The same experiment as in Example 9 was carried out, except for using bis(ethylamino)diisopropylsilane obtained in Example 3 instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 4.
  • Example 9 The same experiment as in Example 9 was carried out, except for using bis(methylamino)-t-butylmethylsilane obtained in Example 4 instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 4.
  • Example 9 The same experiment as in Example 9 was carried out, except for using bis(methylamino)dicyclohexylsilane obtained in Example 5 instead of bis(ethylamino)dicyclopentylsilane.
  • the molecular weight distribution of the polymer was measured. The results are shown in Table 4.
  • Example 9 The same experiment as in Example 9 was carried out, except for using bis(methylamino)cyclohexylmethylsilane obtained in Example 6 instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 4.
  • Example 9 The same experiment as in Example 9 was carried out, except for using bis(methylamino)bis(decahydronaphthyl)silane obtained in Example 7 instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 4.
  • Example 9 The same experiment as in Example 9 was carried out, except for using bis(ethylamino)cyclohexylcyclopentylsilane obtained in Example 8 instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 4.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 9, except for using the solid catalyst component prepared above. The results are shown in Table 4.
  • the solid was separated from the liquid at 95° C., washed twice with 48 ml of toluene, and again treated with a mixture of diisobutyl phthalate and titanium tetrachloride under the same conditions as above.
  • the resulting solid was washed eight times with 48 ml of hexane, filtered, and dried to obtain a solid catalyst component in the form of a powder.
  • the content of titanium in the solid catalyst component was analyzed and found to be 2.1 wt %.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 9, except for using the solid catalyst component prepared above. The results are shown in Table 4.
  • Example 9 The same experiment as in Example 9 was carried out except for extending the reaction time from one hour to two hours. The results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that tris(methylamino)-t-butylsilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • Table 5 The results are shown in Table 5.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that bis(methylamino)-di-t-butylsilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 5.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that bis(methylamino)cyclohexylcyclopentylsilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 5.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that bis(methylamino)cyclohexylthexylsilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 5.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that bis(ethylamino)-t-butylisobutylsilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 5.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that bis(methylamino)-di-4-methoxyphenylsilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 5.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that bis(methylamino)thexylmethylsilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 5.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that bis(methylamino)didecahydronaphthylsilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 5.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that tris(methylamino)cyclohexylsilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 5.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that cyclohexylmethyldimethoxysilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that bis(diethylamino)dimethoxysilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that diisopropylaminotriethoxysilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that tris(dimethylamino)methoxysilane was used instead of bis(ethylamino)dicyclopentylsilane.
  • Table 4 The results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that cyclohexylmethyldimethoxysilane was used instead of bis(ethylamino)dicyclopentylsilane and the polymerization time was extended from one hour to two hours.
  • the results are shown in Table 4.
  • Bis(methylamino)dicyclopentylsilane was synthesized in the same manner as in Example 1, except that methylamine was used instead of ethylamine. The yield was 82.5%. This product was confirmed to be bis(methylamino)dicyclopentylsilane by the elementary analysis. The elementary analysis confirmed that the compound consists of C, 63.53% (63.65%), H, 11.56% (11.57%), and N, 12.35% (12.37%) wherein the percentages of the parentheses are theoretical values.
  • Bis(n-propylamino)dicyclopentylsilane was synthesized in the same manner as in Example 1, except that n-propylamine was used instead of ethylamine. The yield was 82.5%. This product was confirmed to be bis(n-propylamino)dicyclopentylsilane by the elementary analysis. The elementary analysis confirmed that the compound consists of C, 68.03% (68.02%), H, 12.15% (12.13%), and N, 9.90% (9.91%) wherein the percentages of the parentheses are theoretical values.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that bis(methylamino)dicyclopentylsilane prepared in Example 29 was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 4.
  • a solid catalyst component was prepared, a polymerization catalyst was prepared, and polymerization was carried out in the same manner as in Example 9, except that bis(n-propylamino)dicyclopentylsilane prepared in Example 30 was used instead of bis(ethylamino)dicyclopentylsilane.
  • the results are shown in Table 4.
  • the mixture was heated to 40° C. and reacted for one hour. After the reaction, the reaction mixture was filtered in a nitrogen gas atmosphere and the solid components were washed with 10 ml of toluene, thereby separating a solid from liquid.
  • the resulting toluene solution was concentrated under reduced pressure at 50° C. to a volume of one fourth of the original volume, and 150 ml of dehydrated/deoxidized n-heptane was added. The mixture was cooled to 10° C. and allowed to stand overnight to recrystallize a solid. The precipitated needle-like crystals were collected by filtration and dried under nitrogen gas atmosphere to obtain tetrakis(methylamino)silane. Based on the weight of crystals, the yield of first recrystallization was confirmed to be 50%. The residue was subjected to second recrystallization and the resulting crystals were added. The yield became 55%. As a result of elementary analysis, the compound was found to consist of C, 32.23% (32.40%), H, 10.67% (10.88%), and N, 37.70% (37.78%), wherein the percentages of the parentheses are theoretical values.
  • a flask of which the internal atmosphere was sufficiently purged with nitrogen gas was charged with 50 ml of a toluene solution containing 0.2 mol of t-butylamine and cooled to ⁇ 10° C. while stirring.
  • 60 ml of a THF solution containing 0.2 mol of BuMgCl was slowly added to the cooled solution using a dripping funnel.
  • the mixture was gradually heated and reacted at 40° C. for two hours to complete the reaction.
  • a flask of which the internal atmosphere was sufficiently purged with nitrogen gas was charged with 50 ml of a toluene solution containing 0.1 mol of tetramethoxysilane and cooled to ⁇ 10° C. while stirring.
  • a slurry of Mg salt of t-butylamine obtained by the above reaction was slowly added using a dripping funnel. After the addition, the mixture was gradually heated and reacted at 50° C. for three hours. The produced solid was separated from liquid by centrifugation in a nitrogen stream. The solid was washed twice with 20 ml of toluene and added to the solution. The solvent was evaporated under reduced pressure. The residue was distilled under reduced pressure to purify bis(t-butylamino)dimethoxysilane which is the main product.
  • a flask of which the internal atmosphere was sufficiently purged with nitrogen gas was charged with 50 ml of a toluene solution containing 0.1 mol of ethylamine and cooled to ⁇ 10° C. while stirring.
  • 60 ml of a THF solution containing 0.1 mol of BuMgCl was slowly added to the cooled solution using a dripping funnel. After the addition, the mixture was gradually heated and reacted at 20° C. for two hours to complete the reaction.
  • Bis(perhydroquinolino)dimethoxysilane was synthesized by a general synthesis method.
  • 110 ml of a reaction mixture containing 0.1 mol of Mg salt of diethylamine was produced according to the method of Example 34.
  • a flask of which the internal atmosphere was sufficiently purged with nitrogen gas was charged with 80 ml of a toluene solution containing 0.05 mol of bis(perhydroquinolino)dimethoxysilane and cooled to ⁇ 10° C. while stirring.
  • 110 ml of the slurry-like reaction mixture containing 0.1 mol of Mg salt of diethylamine was slowly added to the above solution using a dripping funnel.
  • the mixture was reacted at 60° C. for six hours.
  • the produced solid was separated by centrifugation in a nitrogen stream.
  • the solid was washed twice with 20 ml of toluene and added to the solution.
  • the solvent was evaporated under reduced pressure.
  • the residue was distilled under reduced pressure to purify bis(perhydroquinolino)bis(ethylamino)silane which is the main product.
  • the compound was found to consist of C, 67.20% (67.29%), H, 11.30% (11.29%), and N, 14.25% (14.27%), wherein the percentages of the parentheses are theoretical values.
  • a three-necked flask of which the internal atmosphere was sufficiently purged with nitrogen gas was charged with 80 ml of a toluene solution containing 0.05 mol of di-t-butylamine in a nitrogen stream and cooled to ⁇ 10° C. while stirring.
  • 50 ml of a THF solution containing 0.05 mol of BuMgCl was slowly added to the above toluene solution containing di-t-butylamine using a dripping funnel. After the addition, the mixture was heated to 40° C. and reacted for two hours, thereby obtaining a slurry of Mg salt of di-t-butylamine.
  • Example 35 In the same manner as in Example 35, a slurry containing 0.09 mol of Mg salt of diethylamine synthesized from diethylamine and BuMgCl was slowly added to the above toluene solution containing 0.03 mol of (di-t-butylamino)trimethoxysilane using a dripping funnel. After the addition, the mixture was gradually heated and reacted at 50° C. for four hours. After the reaction, the solid was separated from the solution by centrifugation in a nitrogen stream, washed twice with 20 ml of toluene, and added to the solution.
  • a slurry of 0.1 mol of Mg salt of di-t-butylamine was prepared in the same synthesis method of Example 36.
  • a three-necked flask of which the internal atmosphere was sufficiently purged with nitrogen gas was charged with 50 ml of a toluene solution containing 0.05 mol of tetramethoxysilane in a nitrogen stream and cooled to ⁇ 10° C. while stirring.
  • 100 ml of the above-mentioned slurry of 0.1 mol of Mg salt of di-t-butylamine was slowly added using a dripping funnel to the toluene solution. After the addition, the mixture was reacted at 60° C. for four hours.
  • a three-necked flask of which the internal atmosphere was sufficiently purged with nitrogen gas was charged with a toluene solution containing 0.04 mol of bis(di-t-butylamino)dimethoxysilane in a nitrogen stream and cooled to ⁇ 10° C. while stirring.
  • 80 ml of the above-mentioned slurry of 0.08 mol Mg salt of methylamine was slowly added using a dripping funnel to this solution. After the addition, the mixture was gradually heated and reacted at 70° C. for five hours. After the reaction, a solid was separated by centrifugation in a nitrogen stream. The solid was washed twice with 20 mol of toluene and added to the solution.
  • a three-necked flask in which the internal atmosphere was sufficiently replaced with nitrogen gas was charged with 50 ml of a THF solution containing 0.05 mol of ethylamine. The solution was cooled to ⁇ 10° C. and 5 ml of a hexane solution of BuLi, in an amount equimolar to ethylamine (0.01 mol/ml solution), was added dropwise to obtain Li salt of ethylamine.
  • a heptane solution containing 0.025 mmol of bis(perhydroisoquinolino)dimethoxysilane which was cooled to ⁇ 10° C. was added dropwise to the reaction mixture. After the addition, the mixture was gradually heated and reacted at 50° C.
  • a three-necked flask in which the internal atmosphere was sufficiently replaced with nitrogen gas was charged with 50 ml of a THF solution of diethylamine (0.1 mol/50 ml). The solution was cooled to ⁇ 10° C. while stirring and 100 ml of a THF solution of BuMgCl (0.1 mol/100 ml) was slowly added dropwise using a dripping funnel. After the addition, the mixture was reacted at 40° C. for two hours to complete the reaction.
  • a slurry of Mg salt of diethylamine obtained in this manner was slowly added to 50 ml of a 0.09 mol/50 ml toluene solution of tetrakis(ethylamino)silane synthesized according to the method of Example 33 at ⁇ 10° C. while stirring. After the addition, the mixture was allowed to react at 50° C. for two hours. The reaction product was centrifuged in a nitrogen stream to separate a solid from liquid. The solid was washed twice with toluene. The solution was concentrated and purified by distillation under reduced pressure.
  • Tris(ethylamino)(diethylamino)silane thus obtained was subjected to elementary analysis to confirm that the compound consists of C, 41.32% (51.67%), H, 12.10% (12.14%), and N, 23.98% (24.10%), wherein the percentages of the parentheses are theoretical values.
  • a three-necked flask in which the internal atmosphere was sufficiently replaced with nitrogen gas was charged with 100 ml of a THF solution of diethylamine (0.1 mol/50 ml). The solution was cooled to ⁇ 10° C. and 200 ml of a THF solution of BuMgCl (0.1 mol/100 ml) was slowly added dropwise using a dripping funnel. After the addition, the mixture was reacted at 40° C. for two hours to complete the reaction.
  • a slurry of Mg salt of diethylamine obtained in this manner was slowly added to 50 ml of a 0.09 mol/50 ml toluene solution of tetrakis(ethylamino)silane synthesized according to the method of Example 33 at ⁇ 10° C. while stirring. After the addition, the mixture was reacted at 60° C. for three hours. The reaction product was centrifuged in a nitrogen stream to separate a solid from liquid. The solid was washed twice with toluene. The solution was concentrated and purified by distillation under reduced pressure.
  • a three-necked flask in which the internal atmosphere was sufficiently replaced with nitrogen gas was charged with 50 ml of a THF solution of t-butylethylamine (0.05 mol/50 ml).
  • the solution was cooled to ⁇ 10° C. while stirring and 50 ml of a THF solution of BuMgCl (0.05 mol/50 ml) was slowly added dropwise using a dripping funnel. After the addition, the mixture was reacted at 40° C. for two hours.
  • a slurry of Mg salt of t-butylethylamine obtained in this manner was added dropwise to a flask cooled to ⁇ 10° C., which contained 50 ml of a 0.05 mol/50 ml toluene solution of tetrakis(methylamino)silane synthesized in the same manner as in Example 33. After the addition, the mixture was reacted at 50° C. for two hours. The resulting reaction mixture was concentrated to about one half of the original volume under reduced pressure at room temperature, and the solid was separated from liquid by centrifugation in a nitrogen stream. The solid was washed twice with 15 ml of toluene.
  • Tris(methylamino)(t-butylethylamino)silane thus obtained was subjected to elementary analysis to confirm that the compound consists of C, 49.41% (49.49%), H, 12.01% (12.00%), and N, 25.61% (25.65%), wherein the percentages of the parentheses are theoretical values.
  • a three-necked flask of which the internal atmosphere was sufficiently purged with nitrogen gas was charged with 80 ml of a toluene solution containing 0.05 mol of diisopropylamine in a nitrogen stream and cooled to ⁇ 10° C. while stirring.
  • 50 ml of a THF solution containing 0.05 mol of BuMgCl was slowly added to the above toluene solution containing diisopropylamine using a dripping funnel. After the addition, the mixture was heated to 50° C. and reacted for two hours, thereby obtaining a slurry of Mg salt of diisopropylamine.
  • Example 9 The same experiment as in Example 9 was carried out, except for using tetrakis(methylamino)silane obtained in Example 33 instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 43 The experiment was carried out in the same manner as in Example 43, except that the amount of hydrogen gas used for preparing the polymerization catalyst and carrying out the polymerization reaction was decreased to 1 l from 4 l. The results are shown in Table 6.
  • Example 9 The same experiment as in Example 9 was carried out, except for using 0.13 mmol of bis(t-butylamino)bis(diethylamino)silane obtained in Example 34 instead of 0.26 mmol of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 9 The same experiment as in Example 9 was carried out, except for using 0.13 mmol of bis(perhydroquinolino)bis(diethylamino)silane obtained in Example 35 instead of 0.26 mmol of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 9 The same experiment as in Example 9 was carried out, except for using 0.13 mmol of tris(ethylamino)di-t-butylaminosilane obtained in Example 36 instead of 0.26 mmol of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 9 The same experiment as in Example 9 was carried out, except for using 0.13 mmol of bis(di-t-butylamino)bis(methylamino)silane obtained in Example 37 instead of 0.26 mmol of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 9 The same experiment as in Example 9 was carried out, except for using 0.13 mmol of bis(ethylamino)bis(perhydroisoquinolino)silane obtained in Example 38 instead of 0.26 mmol of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 9 The same experiment as in Example 9 was carried out, except for using 0.13 mmol of tris(ethylamino)bis(diethylamino)silane obtained in Example 39 instead of 0.26 mmol of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 9 The same experiment as in Example 9 was carried out, except for using 0.13 mmol of bis(ethylamino)bis(diethylamino)silane obtained in Example 40 instead of 0.26 mmol of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 9 The same experiment as in Example 9 was carried out, except for using tris(methylamino)(t-butylethylamino)silane obtained in Example 41 instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 9 The same experiment as in Example 9 was carried out, except for using tris(methylamino)diisopropylaminosilane obtained in Example 42 instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 17 The same experiment as in Example 17 was carried out, except for using tetrakis(methylamino)silane obtained in Example 33 instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 18 The same experiment as in Example 18 was carried out, except for using tetrakis(methylamino)silane obtained in Example 33 instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 6.
  • Example 9 The same experiment as in Example 9 was carried out, except for using tris(methylamino)(diethylamino)silane instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 7.
  • Example 9 The same experiment as in Example 9 was carried out, except for using tris(methylamino)(di-4-methoxyphenylamino)silane instead of bis(ethylamino)dicyclopentylsilane. The results are shown in Table 7.
  • Example 9 The same experiment as in Example 9 was carried out, except for using tris(methylamino)(dicyclohexylamino)silane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 7.
  • Example 9 The same experiment as in Example 9 was carried out, except for using tris(methylamino)(cyclohexylamino)silane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 7.
  • Example 9 The same experiment as in Example 9 was carried out, except for using (methylamino)(ethylamino)diisopropylsilane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • Example 9 The same experiment as in Example 9 was carried out, except for using (methylamino)(n-propylamino)diisopropylsilane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • Example 9 The same experiment as in Example 9 was carried out, except for using (methylamino)(ethylamino)dicyclopentylsilane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • Example 9 The same experiment as in Example 9 was carried out, except for using (methylamino)(n-propylamino)dicyclopentylsilane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • Example 9 The same experiment as in Example 9 was carried out, except for using (methylamino)(ethylamino) t -butylethylsilane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • Example 9 The same experiment as in Example 9 was carried out, except for using (methylamino)(n-propylamino)t-butylethylsilane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • Example 9 The same experiment as in Example 9 was carried out, except for using (methylamino)(ethylamino)di-t-butylsilane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • Example 9 The same experiment as in Example 9 was carried out, except for using (methylamino)(n-propylamino)di-t-butylsilane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • Example 9 The same experiment as in Example 9 was carried out, except for using (methylamino)(n-propylamino)(t-butylamino)ethylsilane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • Example 9 The same experiment as in Example 9 was carried out, except for using (methylamino)(n-propylamino)bis(isoquinolyl)silane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • Example 9 The same experiment as in Example 9 was carried out, except for using (methylamino)(ethylamino)bis(diethylamino)silane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • Example 9 The same experiment as in Example 9 was carried out, except for using bis(methylamino)(n-propylamino)(diethylamino)silane instead of bis(ethylamino)dicyclopentylsilane.
  • the polymerization results are shown in Table 8.
  • a flask in which the internal atmosphere was sufficiently replaced with highly pure nitrogen gas was charged with a THF solution of methylamine.
  • the solution was cooled to ⁇ 10 to 0° C. and a hexane solution of commercially available butyl lithium, in an amount equimolar to ethylamine, was slowly added using a dripping funnel while stirring. After the addition, the temperature was gradually increased to 50° C. and the mixture was reacted for two hours to obtain a slurry of lithium salt of methylamine.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 9, except for using 2,2-di(isobutyl)-1,3-dimethoxypropane instead of di-n-butyl phthalate. The results are shown in Table 4.
  • a polymerization catalyst was prepared and polymerization was carried out in the same manner as in Example 9, except for using diethyl 2,3-n-propylsuccinate instead of di-n-butyl phthalate. The results are shown in Table 4.
  • Example 9 bis(ethylamino)dicyclopentylsilane 50,200 97.5 0.44 170 162
  • Example 10 bis(methylamino)-t-butylethylsilane 48,600 98.2 0.44 85
  • Example 11 bis(ethylamino)diisopropylsilane 49,800 97.5 0.44 179
  • Example 12 bis(methylamino)-t-butylmethylsilane 47,800 98.1 0.44 80
  • Example 13 bis(methylamino)dicyclohexylsilane 50,100 97.5 0.44 72
  • Example 14 bis(methylamino)cyclohexylmethylsilane 46,100 97.5 0.44 89
  • Example 15 bis(methylamino)bis(decahydronaphthyl)silane
  • Example 20 tris(methylamino)-t-butylsilane 42,000 97.8 0.44 200 —
  • Example 21 Bis(methylamino)-di-t-butylsilane 49,800 97.6 0.44 140 11
  • Example 22 bis(methylamino)cyclohexylcyclopentylsilane 50,000 97 0.44 160 —
  • Example 23 bis(methylamino)cyclohexylthexylsilane 49,200 97 0.44 100 5
  • Example 24 bis(ethylamino)-t-butylisobutylsilane 47,800 97.5 0.44 135 —
  • Example 25 bis(methylamino)-di-4-methoxyphenylsilane 42,000 96.8 0.44 120 —
  • Example 26 bis(methylamino)thexylmethyls
  • Example 56 Tris(methylamino)(diethylamino)silane 37,500 97.1 0.44 160 —
  • Example 57 tris(methylamino)(di-4-methoxyphenylamino)silane 31,000 97 0.44 130 —
  • Example 58 tris(methylamino)(dicyclohexylamino)silane 36,000 97 0.44 180 —
  • Example 59 bis(methylamino)bis(t-butylamino)silane 42,200 97.3 0.44 180 —
  • Example 60 bis(methylamino)bis(perhydroisoquinolino)silane 32,800 97.5 0.44 75 13
  • Example 61 tris(ethylamino)(perhydroisoquinolino)silane 41,000 97 0.44 200 —
  • Example 62 tris(ethylamino)(perhydroisoquinolino)silane 41,000 97 0.44 200 —
  • Example 63 (methylamino)(ethylamino)diisopropylsilane 46,400 97.6 0.44 180 8
  • Example 64 (methylamino)(n-propylamino)diisopropylsilane 43,300 97.2 0.44 185 9
  • Example 65 (methylamino)(ethylamino)dicyclopentylsilane 49,000 97.1 0.44 165 10.3
  • Example 66 (methylamino)(n-propylamino)dicyclopentylsilane 48,200 96.1 0.44 195 10.4
  • Example 67 (methylamino)(ethylamino)-t-butylethylsilane 43,900 97.3 0.44 100 8.8
  • Example 68 (methylamino)(n-propylamino)-t-t-
  • the molecular weight distribution was measured only for polymers prepared in Examples 13, 15, 16, 21, 23, 27, 31, 32, 46, 47, 48, 49, 52, and 60, and Comparative Example 1. It can be seen from the above results that polymers with high stereoregularity can be obtained in a high yield and excellent hydrogen response can be obtained by using an aminosilane compound in the polymerization. It was also found that some aminosilane compounds can broaden the molecular weight distribution of the resulting polymer.
  • the novel aminosilane compound and specific aminosilane compounds of the present invention can highly maintain stereoregularity and yield of the polymers and can exhibit excellent hydrogen response when compared with the general catalysts. Therefore, owing to the capability of reducing the amount of hydrogen used for the polymerization and high catalyst activity, the catalyst is expected not only to produce polyolefins for common use at a low cost, but also to be useful in the manufacture of olefin polymers having high functions.

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KR20080017412A (ko) 2008-02-26
ES2389665T3 (es) 2012-10-30
JPWO2006129773A1 (ja) 2009-01-08
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US20120053310A1 (en) 2012-03-01
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EP1908767A4 (en) 2010-09-01
SG162730A1 (en) 2010-07-29

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