WO1995029939A1 - Organosilicon compound, ziegler-natta catalyst containing the same and process for polymerization of olefins - Google Patents

Organosilicon compound, ziegler-natta catalyst containing the same and process for polymerization of olefins Download PDF

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Publication number
WO1995029939A1
WO1995029939A1 PCT/JP1995/000847 JP9500847W WO9529939A1 WO 1995029939 A1 WO1995029939 A1 WO 1995029939A1 JP 9500847 W JP9500847 W JP 9500847W WO 9529939 A1 WO9529939 A1 WO 9529939A1
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WIPO (PCT)
Prior art keywords
compound
polymerization
catalyst component
carbon atoms
olefins
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PCT/JP1995/000847
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French (fr)
Inventor
Motoki Hosaka
Kenji Goto
Masahiko Matsuo
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Toho Titanium Co., Ltd.
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Publication date
Priority claimed from JP6113754A external-priority patent/JPH07292029A/en
Priority claimed from JP30996294A external-priority patent/JPH08143580A/en
Application filed by Toho Titanium Co., Ltd. filed Critical Toho Titanium Co., Ltd.
Priority to KR1019960706084A priority Critical patent/KR100347077B1/en
Priority to BR9507522A priority patent/BR9507522A/en
Publication of WO1995029939A1 publication Critical patent/WO1995029939A1/en

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    • 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
    • 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
    • C07F7/18—Compounds having one or more C—Si linkages as well as one or more C—O—Si linkages
    • C07F7/1804—Compounds having Si-O-C linkages
    • 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 relates to an organosilicon compound usable as a silane coupling agent or as a component of an olefin polymerization catalyst and to a Ziegler-Natta catalyst containing the organosilicon compound as an effective electron donor ingredient for the polymerization of olefins with which an olefin polymer having high stereoregularity and broad molecular weight distribution can be obtained in high yield.
  • the present invention also relates to a process for polymerizing an olefin in the presence of the catalyst.
  • U.S. Patent 4,977,291 proposes a process for producing a silicon compound having at least one cycloalkyl group in which a silicon compound containing an aromatic group as a starting compound is hydrogenated in the presence of a catalyst, e.g., a Raney nickel catalyst.
  • a catalyst e.g., a Raney nickel catalyst.
  • U.S. Patent 4,958,041 discloses a process for producing a diorganodialkoxysilane having at least one branched alkyl group other than the two alkoxy groups in which a tetraalkoxy- silane or a monoorganotrialkoxysilane is reacted with a Grignard reagent having the structural formula RMgX wherein R is an alkyl group or a cycloalkyl group and X is a halogen atom.
  • a cycloalkoxysilane represented by the formula (R'0) x (R' ) y Si(OR) 4 .
  • x _ y for use as an electron donor component of a Ziegler-Natta catalyst for olefin polymerization, wherein each R is independently selected from alkyl groups having 1 to 5 carbon atoms and acyl groups having 2 to 5 carbon atoms, each R' is independently selected from a cyclopentyl group, a cyclohexyl group, a cycloheptyl group, and substituted groups thereof, x is 1, 2, 3, or 4, and y is 0, 1 . or 2.
  • JP-A as used herein means an "unexamined published Japanese patent application.”
  • JP-A-5-310757 discloses tert-butoxycyclopentyldiethoxysilane as a novel silane compound and a process for producing the same.
  • examples of conventional olefin polymerization techniques employing a Ziegler-Natta catalyst containing an organosilicon compound as one component thereof include the method disclosed in JP-A-57-63310 and JP-A-57-63311 in which method a catalyst comprising a combination of (a) a solid catalyst component composed of a magnesium compound, a titanium compound and an internal electron donor, (b) an organoaluminum compound, and (c) an organosilicon compound having an Si-O-C bond as an external electron donor is used to polymerize an olefin having 3 or more carbon atoms.
  • this method is not always satisfactory in obtaining a highly stereoregular polymer in high yield, so that a further improvement has been desired.
  • JP-A-63-3010 discloses a catalyst system for the polymerization of olefins and a process for polymerizing olefins using the same, the catalyst system comprising (a) a solid catalyst component prepared by bringing a dialkoxymagnesium, an diester of aromatic dicarboxylic acid, an aromatic hydrocarbon, and a titanium halide into contact and subjecting the resulting product in a powdered state to a heat treatment, (b) an organoaluminum compound, and (c) an organo- silicon compound.
  • JP-A-1-315406 discloses a catalyst system for olefin polymerization and a process for polymerizing an olefin using the same, the catalyst system comprising (a) a solid catalyst component prepared by bringing titanium tetrachloride into contact with a suspension of diethoxymagnesium in an alkyl- benzene, adding phthalic acid dichloride thereto to react to obtain a solid product, and further contacting the resulting solid product with titanium tetrachloride in the presence of an alkylbenzene, (b) an organoaluminum compound, and (c) an organosilicon compound.
  • a solid catalyst component prepared by bringing titanium tetrachloride into contact with a suspension of diethoxymagnesium in an alkyl- benzene, adding phthalic acid dichloride thereto to react to obtain a solid product, and further contacting the resulting solid product with titanium tetrachloride in the presence of an alkylbenzene,
  • JP-A-2-84404 proposes a catalyst system for the polymerization of olefins and a process for homo- or copolymerizing an olefin(s) using the same, the catalyst system comprising (a) a solid titanium catalyst component essentially containing magnesium, titanium and a halogen which is prepared by bringing a magnesium compound and a titanium compound into contact, (b) an organoaluminum compound and (c) an organosilicon compound containing a cyclopentyl group or a derivative thereof, a cyclopentenyl group or a derivative thereof, or a cyclopentadienyl group or a derivative thereof.
  • Each of these known techniques aims at such high catalytic activity that a step of removing residual catalyst components, such as chlorine and titanium, from the resulting polymer (a so-called deashing step) may be omitted and, at the same time, an improvement in yield of a stereoregular polymer or an improvement in durability of the catalytic activity for polymerization, and has achieved excellent results to their purpose.
  • the olefin polymers obtained by polymerization using these catalyst systems comprising such a highly active catalyst component, an organoaluminum compound and an organosilicon compound have narrower molecular weight distribution as compared with those obtained by using conventional catalyst systems comprising a titanium trichloride type catalyst component in combination with an organoaluminum compound and, if desired, an electron donor compound as a third component.
  • a titanium trichloride type catalyst component in combination with an organoaluminum compound and, if desired, an electron donor compound as a third component.
  • the conventional catalyst is used in an attempt to obtain a polyolefin having a broad molecular weight distribution, on the other hand, it results in reduced yield of highly stereoregular polymer which generally has a high melting point.
  • JP-A-3-7703 discloses a process for polymerizing an olefin in the presence of a catalyst system comprising (a) a solid titanium catalyst component essentially containing magnesium, titanium, a halogen, and an electron donor, (b) an organoaluminum compound, and (c) at least two organosilicon compounds as an electron donor.
  • a catalyst system comprising (a) a solid titanium catalyst component essentially containing magnesium, titanium, a halogen, and an electron donor, (b) an organoaluminum compound, and (c) at least two organosilicon compounds as an electron donor.
  • An object of the present invention is to provide a novel organosilicon compound extremely useful as a component of a catalyst, in particular a catalyst for the polymerization of an olefin such as propylene or ethylene, with which catalyst a polymer having a broad molecular weight distribution and high crystallinity can be obtained while maintaining especially high catalytic activity and an extremely high yield of highly stereoregular polymer.
  • a further object of the present invention is to provide a Ziegler-Natta catalyst for olefin polymerization which comprises the organosilicon compound as an effective electron donor ingredient.
  • Another object of the present invention is to provide a process for polymerizing an olefin to produce a polyolefin having broad molecular weight distribution and high stereo ⁇ regularity in high yield.
  • R 1 and R 2 which may be the same or different, each represent an alkyl group having from 1 to 3 carbon atoms;
  • R 3 and R* which may be the same or different, each represents an alkyl group having from 1 to 3 carbon atoms or a halogen atom;
  • m and n each represents 0 or an integer of 1 or 2.
  • Fig. 1 is a chart showing the results of MS with which cyclohexylcyclopentyldimethoxysilane was identified.
  • Fig. 2 is a chart showing the results of two- dimensional analysis by ⁇ -NMR/ ⁇ C-NMR (COSY spectrum) with which cyclohexylcyclopentyldimethoxysilane was identified.
  • Fig. 3 is a chart showing the results of IR with which cyclohexylcyclopentyldimethoxysilane was identified.
  • Examples of the alkyl group for R 1 and R 2 in formula (I) include methyl, ethyl, n-propyl, and isopropyl. Of these, methyl and ethyl are preferred.
  • the organosilicon compound of the present invention is an asymmetric organosilicon compound having a cyclohexyl group
  • cyclohexylcyclopentyldialkoxysilane include cyclohexyl- cyclopentyldimethoxysilane, cyclohexylcyclopentyldiethoxy- silane, cyclohexylcyclopentyldi-n-propoxysilane, and cyclo- hexylcyclopentyldiisopropoxysilane.
  • cyclohexyl- cyclopentyldimethoxysilane and cyclohexylcyclopentyldiethoxy- silane are preferred organosilicon compounds for use as an electron donor serving as a component of an olefin polymerization catalyst.
  • asymmetric organosilicon compounds are included within the scope of formula (I) .
  • substituents (R 3 ) such as a methyl group, chlorine or bromine, at the 3-, 4- or 5- position of the cyclohexyl group thereof and/or one or two substituents (R 4 ) as exemplified above at the 2-, 3- or 5-position of the cyclopentyl group thereof are preferred.
  • Two substituents may be at the same position of the cyclohexyl or cyclopentyl group.
  • plurality of the substituent R 3 or R 4 may be the same or different.
  • derivatives of the asymmetric organosilicon compounds are 3-methylcyclohexylcyclopentyl- dimethoxysilane, 3-methylcyclohexylcyclopentyldiethoxysilane, 3-methylcyclohexylcyclopentyldipropoxysilane, 4-methylcyclo- hexylcyclopentyldimethoxysilane, 4-methylcyclohexylcyclo- pentyldiethoxysilane, 4-methylcyclohexylcyclopentyldipropoxy- silane, 3,5-dimethylcyclohexylcyclopentyldimethoxysilane, 3,5- dimethylcyclohexylcyclopentyldiethoxysilane, 3,5-dimethyl- cyclohexylcyclopentyldipropoxysilane, 3,3-dimethylcyclohexyl- cyclopentyldimethoxysilane,4,4-dimethylcyclohex
  • asymmetric organosilicon compounds are., cyclohexylcyclopentyldimethoxysilane, cyclohexylcyclo- pentyldiethoxysilane, 3-methylcyclohexylcyclopentyldimethoxy- silane, 4-methylcyclohexylcyclopentyldimethoxysilane, and 3,5- dimethylcyclohexylcyclopentyldimethoxysilane.
  • organosilicon compounds may be used either individually or in combination of two or more thereof.
  • the organosilicon compound of the present invention is useful as an (internal and/or external) electron donor for various olefin polymerization catalysts.
  • the organosilicon compound can be used as an electron donor in the homo- or copolymerization of ethylene, propylene, 1-butene, 1- pentene, 4-methyl-l-pentene, vinylcyclohexane, etc.
  • the organosilicon compound is suitable for use as an electron donor of a catalyst for the homopolymerization of ethylene or propylene or the copolymerization of ethylene and propylene, and the optimal use thereof is as an electron donor of a catalyst for the homopolymerization of propylene or the copolymerization of propylene and ethylene.
  • the cyclohexylcyclopentyldialkoxysilane of the present invention can be prepared by various methods.
  • the organosilicon compound is obtained by the reaction of a monocycloalkyltrialkoxysilane (i.e., monocyclo- hexyl- or monocyclopentyl-trialkoxysilane) with a cycloalkyl Grignard reagent (i.e., a Grignard reagent having a cyclopentyl or cyclohexyl group, respectively) .
  • a monocycloalkyltrialkoxysilane i.e., monocyclo- hexyl- or monocyclopentyl-trialkoxysilane
  • a cycloalkyl Grignard reagent i.e., a Grignard reagent having a cyclopentyl or cyclohexyl group, respectively
  • cyclopentyl chloride (commercial product) is first reacted with magnesium in the presence of a solvent, e.g., an ether such as tetrahydrofuran, diethyl ether, or di-n- butyl ether, to yield a cyclopentyl Grignard reagent (cyclo- pentylmagnesium chloride) .
  • a solvent e.g., an ether such as tetrahydrofuran, diethyl ether, or di-n- butyl ether.
  • This reaction may be carried out at a temperature of from room temperature to 60°C.
  • the cyclo ⁇ pentyl Grignard reagent is then reacted with cyclohexyltri- methoxysilane to obtain cyclohexylcyclopentyldimethoxysilane; this reaction may be conducted in the presence of an ether such as tetrahydrofuran, diethyl ether, or di-n-butyl ether as in the above-described first reaction, or in the presence of an aliphatic hydrocarbon solvent such as hexane or heptane or an aromatic hydrocarbon solvent such as toluene, benzene, or xylene.
  • an ether such as tetrahydrofuran, diethyl ether, or di-n-butyl ether
  • an aliphatic hydrocarbon solvent such as hexane or heptane or an aromatic hydrocarbon solvent such as toluene, benzene, or xylene.
  • This reaction may be carried out at a temperature of from 50°C to 200°C, preferably at a temperature of from 100°C to 200°C or at a temperature of from 100°C to 200°C under boiling or refluxing of the solvent.
  • the monocycloalkyltrialkoxysilane e.g., cyclohexyltrimethoxysilane employed above, for use in the above reaction may be a commercial product, it may be prepared by various known methods. In one method, the desired compound is prepared by reacting cyclohexyltrichlorosilane with methanol to alkoxylate the silane compound with the evolution of hydrogen chloride.
  • cyclohexyltrichlorosilane for use in this reaction may be a commercial product, it may be easily prepared by the hydrosilylation reaction of cyclohexene with trichlorosilane (HSiCl 3 ).
  • Another method for preparing cyclohexyltrimethoxysilane comprises hydrogenating a commercial product of phenyltrimethoxysilane in the presence of a catalyst, e.g., a Raney nickel catalyst.
  • the cyclohexylcyclopentyldimethoxysilane thus produced can be identified by nuclear magnetic resonance spectroscopy ⁇ H-NMR, 13 C-NMR), infrared absorption spectrometry (IR), mass spectrometry (MS), etc.
  • IR spectrometry gives a spectrum having a peak at around 1,100 cm "1 attributable to the Si-O-C bonds.
  • the organosilicon compound of the present invention i.e., a cyclohexylcyclopentyldialkoxysilane, when used as an electron donor serving as one component of a Ziegler-Natta catalyst for olefin polymerization, makes it possible to obtain a polyolefin having a broad molecular weight distribution and high crystallinity while retaining high performances with respect to catalytic activity and the yield of highly stereoregular polymer which performances are not lower than those conventionally known as high-performance catalysts.
  • the Ziegler-Natta catalyst of the present invention is not particularly limited as long as the organosilicon compound of formula (I) is contained as an internal or external electron donor, and any conventional components for the Ziegler-Natta catalyst can be used together with the organosilicon compound.
  • the Ziegler-Natta catalyst comprises (A) a solid catalyst component essentially comprising magnesium, titanium, an electron donor compound, and a halogen which is prepared by contacting a magnesium compound, a titanium halide compound, and an internal electron donor compound, (B) an organoaluminum compound, and (C) the organosilicon compound of formula (I) as an external electron donor.
  • the magnesium compound which can be used for preparing solid catalyst component (A) includes metallic magnesium, a magnesium dihalide, a dialkylmagnesium, an alkylmagnesium halide, a dialkoxymagnesium, a diaryloxymagnesium, and an alkoxymagnesium halide.
  • the alkyl or alkoxy moiety of the above-described magnesium compounds generally has from 1 to 6 carbon atoms and preferably from 1 to 4 carbon atoms.
  • magnesium halide examples include magnesium dichloride, magnesium dibromide, magnesium diiodide, and magnesium difluoride.
  • dialkylmagnesium examples include dimethyl- magnesium, diethylmagnesium, ethylmethylmagnesium, dipropyl- magnesium, methylpropylmagnesium, ethylpropylmagnesium, dibutylmagnesium, butylmethylmagnesium, and butylethyl- magnesium.
  • dialkylmagnesiums may be obtained by reacting metallic magnesium with a halogenated hydrocarbon or an alcohol.
  • alkylmagnesium halide examples include ethylmagnesium chloride, propylmagnesium chloride, and butyl- magnesium chloride. These alkylmagnesium halides may be obtained by reacting metallic magnesium with a halogenated hydrocarbon or an alcohol.
  • dialkoxymagnesium and the diaryloxymagnesium include dimethoxymagnesium, diethoxy- magnesium, dipropoxymagnesium, dibutoxymagnesium, diphenoxy- magnesium, ethoxymethoxymagnesium, ethoxypropoxymagnesium, and butoxyethoxymagnesiu .
  • alkoxymagnesium halide examples include methoxymagnesium chloride, ethoxymagnesium chloride, propoxy- magnesium chloride, and butoxymagnesium chloride.
  • these magnesium compounds are dialkoxy- magnesiums, with diethoxymagnesium and dipropoxymagnesium being especially preferred.
  • the magnesium compounds may be used either individually or in combination of two or more thereof.
  • the dialkoxymagnesium which can be used preferably, is at least one dialkoxymagnesium species having from 1 to 3 carbon atoms in the alkoxy moiety thereof and has a granular or powdered form, the particles of which may have an irregular shape or a spherical shape. In using spherical particles of diethoxymagnesium, the resulting powdered polymer will have a more satisfactory particle shape and a narrower particle size distribution.
  • the polymer powder as produced has improved handling properties, and troubles attributed to fine particles, such as obstruction, would be eliminated.
  • the spherical diethoxymagnesium particles as above referred to do not necessarily need to be true spheres, and ellipsoidal or potato-like particles may also be used.
  • the terminology "spherical” as used herein may be quantified as a longer axis diameter ( Q ) to shorter axis diameter (w) ratio ( ⁇ /w) of not more than 3, preferably from 1 to 2, and still preferably from 1 to 1.5.
  • the dialkoxymagnesium to be used has an average particle size of from 1 to 200 ⁇ m, preferably from 5 to 150 ⁇ m.
  • spherical diethoxymagnesium In the case of spherical diethoxymagnesium, it has an average particle size of from 1 to 100 ⁇ m, preferably from 5 to
  • particles having a sharp size distribution with a small proportion of fine or coarse particles. More specifically, particles containing not more than 20%, preferably not more than 10%, of fine particles of 5 ⁇ m or smaller and not more than 10%, preferably not more than 5%, of coarse particles of 100 ⁇ m or greater.
  • Such a particle size distribution corresponds to In (D 90 /D 10 ) of not more than 3, preferably not more than 2, wherein D 90 and D 10 represent a cumulative 90% diameter and a cumulative 10% diameter, respectively, of a cumulative particle size distribution depicted from the small diameter side.
  • dialkoxymagnesium does not always need to be present as a starting material in the preparation of solid catalyst component (A) .
  • it may be prepared in situ from metallic magnesium and an alcohol in the presence of a catalyst, e.g., iodine at the time of preparing solid catalyst component (A) .
  • the titanium halide compound which can be used for preparing solid catalyst component (A) is at least one of a titanium halide and an alkoxytitanium halide represented by formula: Ti(OR 5 ) n X ⁇ . n , wherein R 5 represents an alkyl group having from 1 to 4 carbon atoms; X represents a chlorine atom, a bromine atom or an iodine atom; and n represents 0 or an integer of 1, 2 or 3.
  • Specific examples of the titanium halide include titanium tetrahalides, such as TiC ⁇ ! 4 , TiBr 4 , and Til 4 .
  • alkoxytitanium halide examples include Ti(OCH 3 )C ⁇ 3 , Ti(OC 2 H 5 )C « 3 , Ti(OC 3 H 7 )C ⁇ 3 , Ti(On-C 4 H 9 )C ⁇ 3 , Ti(OCH 3 ) 2 CH 2 , Ti(OC 2 H 5 ) 2 C ⁇ 2 , Ti(OC 3 H 7 ) 2 C ⁇ 2 , Ti(On-C 4 H 9 ) 2 C ⁇ 2 , Ti(OCH 3 ) 3 C ⁇ , Ti(OC 2 H 5 ) 3 C ⁇ , Ti(OC 3 H 7 ) 3 C0 , and Ti(On-C A H 9 ) 3 CC .
  • titanium halide compounds are titanium tetrahalides, with TiCfl 4 being particularly preferred. These titanium halide compounds may be used either individually or in combination of two or more thereof.
  • the electron donor compound which can be used for preparing solid catalyst component (A) is an organic compound containing oxygen or nitrogen. Such a compound include alcohols, phenols, ethers, esters, ketones, acid halides, aldehydes, amines, amides, nitriles, isocyanates, and organo- silicon compounds containing an Si-O-C bond.
  • the electron donor compound examples include alcohols, such as methanol, ethanol, propanol, butanol, pentanol, hexanol, octanol, 2-ethylhexyl alcohol, and dodecanol; phenols, such as phenol and cresol; ethers, such as dimethyl ether, diethyl ether, dipropyl ether, dibutyl ether, diamyl ether, and diphenyl ether; monocarboxylic acid esters, such as methyl formate, ethyl acetate, vinyl acetate, propyl acetate, octyl acetate, cyclohexyl acetate, ethyl propionate, ethyl butyrate, methyl benzoate, ethyl benzoate, propyl benzoate, butyl benzoate, octyl benzoate, cyclohexyl benzoate, phenol
  • organosilicon compound containing an Si-O-C bond examples include trimethylmethoxysilane, trim- ethylethoxysilane, tri-n-propylmethoxysilane, tri-n-propyl- ethoxysilane, tri-n-butylmethoxysilane, tri-isobutylmethoxy- silane, tri-t-butylmethoxysilane, tri-n-butylethoxysilane, tricyclohexylmethoxysilane, tricyclohexylethoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, di-n-propyl- dimethoxysilane, diisopropyldimethoxysilane, di-n-propyl- diethoxysilane, diisopropyldiethoxysilane, di-n-butyldimethoxy- silane, diisobutyldimethoxy
  • esters preferred are esters, with phthalic diesters being more preferred.
  • the ester moiety in the phthalic diesters is preferably a straight chain or branched chain alkyl group having from 1 to 12 carbon atoms and preferably from 2 to 10 carbon atoms.
  • Suitable phthalic diesters are dimethyl phthalate, diethyl phthalate, di-n-propyl phthalate, diisopropyl phthalate, di-n- butyl phthalate, diisobutyl phthalate, ethyl ethyl phthalate, methylisopropyl phthalate, ethyl-n-propyl phthalate, ethyl-n- butyl phthalate, di-n-pentyl phthalate, diisopentyl phthalate, dihexyl phthalate, di-n-heptyl phthalate, di-n-octyl phthalate, bis(2-methylhexyl)phthalate, bis(2-ethylhexyl) phthalate, di-n- nonyl phthalate, diisodecyl phthalate, bis(2,2-dimethylheptyl) phthalate, n-butylisohexyl
  • phthalic acid esters may be used either individually or in combination of two or more thereof.
  • the preferred combination of the phthalic acid esters is exemplified with: diethyl phthalate and bis(2-ethylhexyl) phthalate; di-n-butyl phthalate and bis(2-ethylhexyl) phthalate; diisobutyl phthalate and bis(2-ethylhexyl) phthalate; and diethyl phthalate, bis(2-ethylhexyl) phthalate and di-n-butyl phthalate.
  • Solid catalyst component (A) can be prepared by contacting the above-mentioned magnesium compound, titanium halide compound and electron donor compound in a manner appropriately selected from conventional means.
  • Known methods for preparing a solid catalyst component are disclosed, e.g., in JP-A-63-308004, JP-A-63-314211, JP-A-64-6006, JP-A-64-14210, JP-A-64-43506, JP-A-63-3010, and JP-A-62-158704.
  • the solid component is reacted with silicon tetrachloride, contacted with phthalic acid dichloride, and reacted with titanium tetrachloride to prepare solid catalyst component (A) .
  • the resulting solid catalyst component may be preliminarily treated with an organo ⁇ aluminum compound, an organosilicon compound, and an olefin.
  • An organomagnesium compound, e.g., dibutylmagnesium, and an organoaluminum compound are brought into contact with an alcohol, e.g., butanol or 2-ethylhexyl alcohol, in the presence of a hydrocarbon solvent to form a uniform solution.
  • the resulting solution is brought into contact with a silicon compound, e.g., SiC ⁇ 4 , HSiC0 3 or polysiloxane, to obtain a solid component.
  • the solid component is brought into contact with titanium tetrachloride and a diester of phthalic acid in the presence of an aromatic hydrocarbon solvent, and the reaction mixture is further brought into contact with titanium tetra ⁇ chloride to obtain solid catalyst component (A) .
  • Diethoxymagnesium is suspended in an alkylbenzene or a halogenated hydrocarbon solvent, and the resulting suspension is brought into contact with titanium tetrachloride.
  • the mixture is heated and then contacted with a diester (e.g., an alkyl ester having 1 to 10 carbon atoms) of phthalic acid to obtain a solid component.
  • the solid component is washed with an alkylbenzene and again contacted with titanium tetrachloride in the presence of the alkylbenzene to prepare solid catalyst component (A) .
  • the resulting solid catalyst component may be subjected to a heat treatment in the presence or absence of a hydrocarbon solvent.
  • Diethoxymagnesium is suspended in an alkylbenzene, and the resulting suspension is brought into contact with titanium tetrachloride and phthalic acid chloride to obtain a solid component.
  • the solid component is washed with an alkylbenzene and again contacted with titanium tetrachloride in the presence of the alkylbenzene to prepare solid catalyst component (A) .
  • the resulting solid catalyst component may further be contacted with titanium tetrachloride twice or more times.
  • a calcium halide and aliphatic magnesium, e.g., magnesium stearate, are contact reacted with titanium tetrachloride and a diester (e.g., an alkyl ester having 1 to 10 carbon atoms) of phthalic acid, and the reaction product is further brought into contact with titanium tetrachloride to prepare solid catalyst component (A) .
  • a diester e.g., an alkyl ester having 1 to 10 carbon atoms
  • Diethoxymagnesium is suspended in an alkylbenzene or a halogenated hydrocarbon solvent, and the resulting suspension is brought into contact with titanium tetrachloride, and the mixture is heated and contacted with a diester (e.g., an alkyl ester having 1 to 10 carbon atoms) of phthalic acid to react.
  • a diester e.g., an alkyl ester having 1 to 10 carbon atoms
  • the resulting solid component is washed with an alkylbenzene and further contacted with titanium tetrachloride in the presence of the alkylbenzene to prepare solid catalyst component (A) .
  • the system may be brought into contact with aluminum chloride.
  • Diethoxymagnesium is suspended in an alkylbenzene or a halogenated hydrocarbon solvent, and the resulting suspension is brought into contact with titanium tetrachloride, and the mixture is heated and contacted with two or more diesters of phthalic acid different in the carbon atom number of the alkyl moiety (e.g., diethyl phthalate and bis(2-ethyhexyl) phthalate) to obtain a solid component.
  • the resulting solid component is washed with an alkylbenzene and further contacted with titanium tetrachloride in the presence of the alkylbenzene to prepare solid catalyst component (A) .
  • the solid component when it is brought into contact with titanium tetrachloride, it may again contacted with two or more diesters of phthalic acid different in the carbon atom number of the alkyl moiety. Further, the diesters of phthalic acid may be used in combination with the above-enumerated electron donor compound other than diesters of phthalic acid.
  • the solution is contacted with titanium tetrachloride and a diester of phthalic acid to obtain a solid component.
  • the solid component is dissolved in tetrahydrofuran, and the solid component is made to precipitate.
  • the resulting solid component is contact reacted with titanium tetrachloride to prepare solid catalyst component. If desired, the contact with titanium tetrachloride may be conducted repeatedly.
  • a silicon compound e.g., tetrabutoxy- silane, may be contacted with the preparation system.
  • the amounts of the magnesium compound, titanium halide compound and electron donor compound to be used for the preparation of solid catalyst component (A) vary depending on the method of preparation and cannot be generally specified.
  • the titanium halide compound is used in an amount of from 0.5 to 100 mol, preferably from 1 to 10 mol, and the electron donor compound from 0.01 to 3 mol, preferably from 0.02 to 1 mol, each per mole of the magnesium compound.
  • the titanium content in solid catalyst component (A) is not particularly limited and it is generally from 0.5 to 10 % by weight, preferably from 1 to 5 % by weight, based on the weight of solid catalyst component (A) .
  • Organoaluminum compound (B) which can be used in the present invention includes compounds represented by general formula: R 7 y AlY 3 _ y , wherein R 7 represents an alkyl group having from 1 to 4 carbon atoms; Y represents a hydrogen atom, a chlorine atom, a bromine atom or an iodine atom; and y represents an integer of 1, 2 or 3.
  • organoaluminum compound (B) examples include triethylaluminum, diethylaluminum chloride, triisobutyl- aluminum, diethylaluminum bromide, and diethylaluminum hydride. These organoaluminum compounds may be used either individually or in combination of two or more thereof. Preferred of them are triethylaluminum and triisobutylaluminum.
  • Organosilicon compound (C) which is preferably used in the present invention includes compounds represented by formula (I).
  • a combined use of the specific organosilicon compound (C) with solid catalyst component (A) and organoaluminum compound (B) makes it possible to produce an olefin polymer having markedly higher stereoregularity and broader molecular weight distribution in higher yield than in using conventional catalysts.
  • an olefin is homo- or copolymerized in the presence of the Ziegler-Natta catalyst comprising solid catalyst component (A) , organoaluminum compound (B), and organosilicon compound (C).
  • the ratio of components (A), (B), and (C) to be used is not particularly limited as long as the effects of the present invention are not impaired.
  • organoaluminum compound (B) is used in an amount of from 1 to 500 mol and preferably from 5 to 400 mol per mol of the titanium atom in solid catalyst component (A), and organosilicon compound (C) is used in an amount of from 0.0020 to 2 mol and preferably from 0.0025 to 0.5 mol per mol of organoaluminium compound (B) .
  • the Ziegler-Natta catalyst of the present invention can be prepared by bringing the above-described components (A), (B) and (C) into contact. There is no particular limitation on the order in contact of the components (A), (B) and (C). In general, the component (B) is brought into contact with the component (C) and subsequently with the component (A), or the component (B) is brought into contact with the component (A) and subsequently with the component (C).
  • Solid Catalyst Component (A) Organo ⁇ (Process of aluminum Organosilicon Preparation ) Compound (B ) Compound (C ) process (7) triethyl ⁇ cyclohexylcyclopentyl- aluminum dimethoxysilane process (7) triethyl ⁇ 3-methyleye1ohexy1- aluminum eyelopentyldimethoxysilane process (8) triethyl ⁇ eye1ohexy1eye1openty1- aluminum dimethoxysilane process (10) triethyl ⁇ eyelohexyleyelopentyl- aluminum dimethoxysilane process (10) triethyl ⁇ 4-methyleye1ohexy1- aluminum cyclopentyldimethoxysilane process (12) triethyl ⁇ cyclohexylcyclopentyl- aluminum dimethoxysilane process (12) triethyl ⁇ 3-methylcyclohexylcyclo- aluminum pentyldime
  • Polymerization reaction according to the present invention may be carried out in the presence or absence of an organic solvent.
  • the olefin monomer to be polymerized may be used in either a gaseous state or a liquid state.
  • the polymerization is conducted at a temperature of not higher than 200°C, preferably not higher than 100°C, under a pressure of not higher than 10 MPa, preferably not higher than 5 MPa.
  • the reaction may be effected either in a continuous system or in a batch system and through one step or two or more steps.
  • the olefins to be homo- or copolymerized according to the present invention are not particularly limited and generally have 2 to 20 carbon atoms, such as ethylene, propylene, 1-butene, 1-pentene, 4-methyl-l-pentene, and vinyl- cyclohexane. These olefins may be used either individually or in combination of two or more thereof.
  • the effects of the present invention in assuring high stereoregularity, broad molecular weight distribution, and high yield are particularly pronounced in homopolymerization of propylene or copolymeriza- tion of propylene and ethylene.
  • Monomers to be pre-polymerized include not only ethylene and propylene but other monomers, such as styrene and vinylcyclohexane.
  • the catalyst of the present invention is used in an amount of about 0.005 to 0.5 mmol, preferably about 0.01 to 0.5 mmol, calculated as titanium atom in solid catalyst component (A) per liter of the polymerization zone.
  • the olefin polymers obtained have a broader molecular weight distribution than those obtained by conventional processes, by at least 1 higher as expressed in terms of the ratio of weight average molecular weight to number average molecular weight (Mw/Mn) of the olefin polymers, and the yield of stereoregular polymers is extremely high. That is, the process has been confirmed to provide polyolefins having not only broad molecular weight distribution (for example, 6 or higher in terms of the Mw/Mn) but high stereoregularity in extremely high yield.
  • MS apparatus ... Finigan Mat (GC-MS).
  • ⁇ -NMR/ ⁇ C-NMR apparatus ... JEOL GSX270, solvent ... CDC1 3 .
  • reaction mixture was washed with two 100 md portions of toluene at 90°C, and 20 mfi of titanium tetrachloride and 80 m ⁇ of toluene were added thereto.
  • the mixture was heated to 100°C, at which it was allowed to react for 2 hours while stirring.
  • the reaction mixture was washed with ten 100 mC portions of n-heptane at 40°C to obtain solid catalyst component (A-l).
  • Mw Weight average molecular weight
  • Mn Number average molecular weight
  • reaction mixture was washed with two 100 itiC portions of toluene at 90°C, and 20 mf of titanium tetrachloride and 80 mC of toluene were added thereto.
  • the mixture was heated to 110°C, at which it was allowed to react for 2 hours while stirring.
  • the reaction mixture was washed ten 100 mC portions of n-heptane at 40°C to obtain solid catalyst component (A-2).
  • Example 2 except for using solid catalyst component (A-3). The reaction results are shown in Table 2.
  • Example 2 except for using solid catalyst component (A-5). The reaction results are shown in Table 2.
  • reaction product was washed twice with 100 ml of toluene heated at 90°C.
  • To the washed reaction product were added 20 ml of titanium tetrachloride and 80 ml of toluene. This mixture was heated to 100°C and stirred for 2 hours to allow a reaction to proceed.
  • the reaction product was washed 10 times with 100 ml of n-heptane warmed at 40°C to obtain a solid catalyst component.
  • the titanium content of this solid catalyst component was measured and found to be 2.46% by weight.
  • the organosilicon compound of the present invention when used as an electron donor serving as one component of an olefin polymerization catalyst, gives a polyolefin having a broad molecular weight distribution and high crystallinity, while retaining high performances with respect to catalytic activity and the yield of highly stereoregular polymer which performances are equal to or higher than those of conventionally known high-performance catalysts.
  • the organosilicon compound therefore is capable of providing at low cost a general-purpose polyolefin excellent in rigidity and moldability.
  • the organosilicon compound of the present invention is expected to be useful as, e.g., a silane coupling agent, a modifier for resins, etc.
  • the Ziegler-Natta catalyst for olefin polymerization comprises (A) a specific solid catalyst component, (B) an organoaluminum compound, and (C) an asymmetric organosilicon compound containing a cyclohexyl group or a derivative thereof and a cyclopentyl group or a derivative thereof.
  • Polymerization of an olefin in the presence of the catalyst of the present invention provides an olefin polymer having high stereoregularity (high yield of total crystalline polymer) and broad molecular weight distribution in high yield.

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Abstract

An organosilicon compound represented by formula (I) wherein R?1 and R2¿, which may be the same or different, each represents an alkyl group having from 1 to 3 carbon atoms; R?3 and R4¿, which may be the same or different, each represents an alkyl group having from 1 to 3 carbon atoms, or a halogen atom; and m and n each represents 0 or an integer of 1 or 2. The organosilicon compound is used as an effective electron donor ingredient of a Ziegler-Natta catalyst for olefin polymerization.

Description

DESCRIPTION
ORGANOSILICON COMPOUND, ZIEGLER-NATTA
CATALYST CONTAINING THE SAME
AND PROCESS FOR POLYMERIZATION OF OLEFINS
FIELD OF THE INVENTION The present invention relates to an organosilicon compound usable as a silane coupling agent or as a component of an olefin polymerization catalyst and to a Ziegler-Natta catalyst containing the organosilicon compound as an effective electron donor ingredient for the polymerization of olefins with which an olefin polymer having high stereoregularity and broad molecular weight distribution can be obtained in high yield. The present invention also relates to a process for polymerizing an olefin in the presence of the catalyst.
BACKGROUND OF THE INVENTION Hitherto, a large number of specific organosilicon compounds for use as an electron donor (external electron donor) as a component of a Ziegler-Natta catalyst or for use as an electron donor (internal electron donor) contained in a solid catalyst component of a Ziegler-Natta catalyst have been proposed for the purpose of producing polymers having improved stereoregularity or enhancing catalytic activity in olefin polymerization using the catalyst.
Various proposals have been made on processes for producing this kind of organosilicon compounds. For example, U.S. Patent 4,977,291 proposes a process for producing a silicon compound having at least one cycloalkyl group in which a silicon compound containing an aromatic group as a starting compound is hydrogenated in the presence of a catalyst, e.g., a Raney nickel catalyst.
U.S. Patent 4,958,041 discloses a process for producing a diorganodialkoxysilane having at least one branched alkyl group other than the two alkoxy groups in which a tetraalkoxy- silane or a monoorganotrialkoxysilane is reacted with a Grignard reagent having the structural formula RMgX wherein R is an alkyl group or a cycloalkyl group and X is a halogen atom. In JP-A-5-255350 is disclosed a cycloalkoxysilane represented by the formula (R'0)x(R' )ySi(OR)4.x_y for use as an electron donor component of a Ziegler-Natta catalyst for olefin polymerization, wherein each R is independently selected from alkyl groups having 1 to 5 carbon atoms and acyl groups having 2 to 5 carbon atoms, each R' is independently selected from a cyclopentyl group, a cyclohexyl group, a cycloheptyl group, and substituted groups thereof, x is 1, 2, 3, or 4, and y is 0, 1 . or 2. The term "JP-A" as used herein means an "unexamined published Japanese patent application." JP-A-5-310757 discloses tert-butoxycyclopentyldiethoxysilane as a novel silane compound and a process for producing the same.
On the other hand, examples of conventional olefin polymerization techniques employing a Ziegler-Natta catalyst containing an organosilicon compound as one component thereof include the method disclosed in JP-A-57-63310 and JP-A-57-63311 in which method a catalyst comprising a combination of (a) a solid catalyst component composed of a magnesium compound, a titanium compound and an internal electron donor, (b) an organoaluminum compound, and (c) an organosilicon compound having an Si-O-C bond as an external electron donor is used to polymerize an olefin having 3 or more carbon atoms. However, this method is not always satisfactory in obtaining a highly stereoregular polymer in high yield, so that a further improvement has been desired.
On the other hand, JP-A-63-3010 discloses a catalyst system for the polymerization of olefins and a process for polymerizing olefins using the same, the catalyst system comprising (a) a solid catalyst component prepared by bringing a dialkoxymagnesium, an diester of aromatic dicarboxylic acid, an aromatic hydrocarbon, and a titanium halide into contact and subjecting the resulting product in a powdered state to a heat treatment, (b) an organoaluminum compound, and (c) an organo- silicon compound.
JP-A-1-315406 discloses a catalyst system for olefin polymerization and a process for polymerizing an olefin using the same, the catalyst system comprising (a) a solid catalyst component prepared by bringing titanium tetrachloride into contact with a suspension of diethoxymagnesium in an alkyl- benzene, adding phthalic acid dichloride thereto to react to obtain a solid product, and further contacting the resulting solid product with titanium tetrachloride in the presence of an alkylbenzene, (b) an organoaluminum compound, and (c) an organosilicon compound.
JP-A-2-84404 proposes a catalyst system for the polymerization of olefins and a process for homo- or copolymerizing an olefin(s) using the same, the catalyst system comprising (a) a solid titanium catalyst component essentially containing magnesium, titanium and a halogen which is prepared by bringing a magnesium compound and a titanium compound into contact, (b) an organoaluminum compound and (c) an organosilicon compound containing a cyclopentyl group or a derivative thereof, a cyclopentenyl group or a derivative thereof, or a cyclopentadienyl group or a derivative thereof. Each of these known techniques aims at such high catalytic activity that a step of removing residual catalyst components, such as chlorine and titanium, from the resulting polymer (a so-called deashing step) may be omitted and, at the same time, an improvement in yield of a stereoregular polymer or an improvement in durability of the catalytic activity for polymerization, and has achieved excellent results to their purpose.
In recent years, however, it has been pointed out that the olefin polymers obtained by polymerization using these catalyst systems comprising such a highly active catalyst component, an organoaluminum compound and an organosilicon compound have narrower molecular weight distribution as compared with those obtained by using conventional catalyst systems comprising a titanium trichloride type catalyst component in combination with an organoaluminum compound and, if desired, an electron donor compound as a third component. For polyolefins to have narrower molecular weight distribution means poorer moldability, leading to less applicability. If the conventional catalyst is used in an attempt to obtain a polyolefin having a broad molecular weight distribution, on the other hand, it results in reduced yield of highly stereoregular polymer which generally has a high melting point.
Various manipulations have been suggested to solve this problem. For example, adoption of a multi-stage polymerization system has been proposed for obtaining polyolefins with broader molecular weight distribution. Nevertheless, a multi-stage polymerization system requires repetition of tedious and complicated operation of polymerization and also involves a step for recovery of a chelating agent to be used for polymerization and is not therefore deemed to be favorable from the considerations of labor and cost.
As the latest technique, JP-A-3-7703 discloses a process for polymerizing an olefin in the presence of a catalyst system comprising (a) a solid titanium catalyst component essentially containing magnesium, titanium, a halogen, and an electron donor, (b) an organoaluminum compound, and (c) at least two organosilicon compounds as an electron donor. According to this process, a polyolefin having broad molecular weight distribution can be obtained without involving laborious multi-stage polymerization operation. However, the use of at least two organosilicon compounds as an electron donor for polymerization makes the process still tedious and complicated.
SUMMARY OF THE INVENTION An object of the present invention is to provide a novel organosilicon compound extremely useful as a component of a catalyst, in particular a catalyst for the polymerization of an olefin such as propylene or ethylene, with which catalyst a polymer having a broad molecular weight distribution and high crystallinity can be obtained while maintaining especially high catalytic activity and an extremely high yield of highly stereoregular polymer. A further object of the present invention is to provide a Ziegler-Natta catalyst for olefin polymerization which comprises the organosilicon compound as an effective electron donor ingredient.
Another object of the present invention is to provide a process for polymerizing an olefin to produce a polyolefin having broad molecular weight distribution and high stereo¬ regularity in high yield.
As a result of extensive studies on olefin polymeriza¬ tion catalysts in order to overcome such problems of conventional techniques, the present inventors have succeeded in developing a novel organosilicon compound which is usable as an internal and/or external electron donor serving as a component of an olefin polymerization catalyst, and they have ascertained that the organosilicon compound is extremely effective. That is, the above objects are accomplished with an organosilicon compound represented by formula (I)
Figure imgf000008_0001
wherein R1 and R2, which may be the same or different, each represent an alkyl group having from 1 to 3 carbon atoms; R3 and R*, which may be the same or different, each represents an alkyl group having from 1 to 3 carbon atoms or a halogen atom; and m and n each represents 0 or an integer of 1 or 2.
BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a chart showing the results of MS with which cyclohexylcyclopentyldimethoxysilane was identified.
Fig. 2 is a chart showing the results of two- dimensional analysis by ^-NMR/^C-NMR (COSY spectrum) with which cyclohexylcyclopentyldimethoxysilane was identified.
Fig. 3 is a chart showing the results of IR with which cyclohexylcyclopentyldimethoxysilane was identified. DETAILED DESCRIPTION OF THE INVENTION Examples of the alkyl group for R1 and R2 in formula (I) include methyl, ethyl, n-propyl, and isopropyl. Of these, methyl and ethyl are preferred.
The organosilicon compound of the present invention is an asymmetric organosilicon compound having a cyclohexyl group
( —\ H) ) or a derivative thereof and a cyclopentyl group
( ( H ) or a derivative thereof both directly bonded to the silicon atom.
Examples of the asymmetric organosilicon compound
(i.e. , cyclohexylcyclopentyldialkoxysilane) include cyclohexyl- cyclopentyldimethoxysilane, cyclohexylcyclopentyldiethoxy- silane, cyclohexylcyclopentyldi-n-propoxysilane, and cyclo- hexylcyclopentyldiisopropoxysilane. Of these, cyclohexyl- cyclopentyldimethoxysilane and cyclohexylcyclopentyldiethoxy- silane are preferred organosilicon compounds for use as an electron donor serving as a component of an olefin polymerization catalyst.
Various derivatives of these asymmetric organosilicon compounds are included within the scope of formula (I) . In particular, those having one or two substituents (R3), such as a methyl group, chlorine or bromine, at the 3-, 4- or 5- position of the cyclohexyl group thereof and/or one or two substituents (R4) as exemplified above at the 2-, 3- or 5-position of the cyclopentyl group thereof are preferred. Two substituents may be at the same position of the cyclohexyl or cyclopentyl group. When m or n in formula (I) is 2, plurality of the substituent R3 or R4 may be the same or different.
Specific examples of the derivatives of the asymmetric organosilicon compounds are 3-methylcyclohexylcyclopentyl- dimethoxysilane, 3-methylcyclohexylcyclopentyldiethoxysilane, 3-methylcyclohexylcyclopentyldipropoxysilane, 4-methylcyclo- hexylcyclopentyldimethoxysilane, 4-methylcyclohexylcyclo- pentyldiethoxysilane, 4-methylcyclohexylcyclopentyldipropoxy- silane, 3,5-dimethylcyclohexylcyclopentyldimethoxysilane, 3,5- dimethylcyclohexylcyclopentyldiethoxysilane, 3,5-dimethyl- cyclohexylcyclopentyldipropoxysilane, 3,3-dimethylcyclohexyl- cyclopentyldimethoxysilane,4,4-dimethylcyclohexylcyclopentyl- dimethoxysilane, cyclohexyl-2-methylcyclopentyldimethoxysilane, cyclohexyl-2-methylcyclopentyldiethoxysilane, cyclohexyl-2- ethylcyclopentyldipropoxysilane,3-methylcyclohexyl-2-methyl- cyclopentyldimethoxysilane, 3-methylcyclohexyl-2-methylcyclo- pentyldiethoxysilane, 3-methylcyclohexyl-2-methylcyclopentyl- dipropoxysilane, 4-methylcyclohexyl-2-methylcyclopentyl- dimethoxysilane, 4-methy1eye1ohexy1-2-me hyleye1openty1- diethoxysilane, 4-methylcyclohexyl-2-methylcyclopentyl- dipropoxysilane, 3,5-dimethylcyclohexyl-2-methylcyclopentyl- dimethoxysilane, 3,5-dimethylcyclohexyl-2-methylcyclopentyl- diethoxysilane, 3,5-dimethylcyclohexyl-2-methylcyclopentyl- dipropoxysilane, 3,3-dimethylcyclohexyl-2-methylcyclopentyl- dimethoxysilane, 4,4-dimethylcyclohexyl-2-methylcyclopentyl- dimethoxysilane, cyclohexyl-3-methylcyclopentyldimethoxysilane, cyclohexyl-3-methylcyclopentyldiethoxysilane, cyclohexyl-3- methylcyclopentyldipropoxysilane,3-methylcyclohexyl-3-methyl- cyclopentyldimethoxysilane, 3-methylcyclohexyl-3-methylcyclo- pentyldiethoxysilane, 3-methylcyclohexyl-3-methylcyclopentyl- dipropoxysilane, 4-methyleye1ohexy1-3-methyleye1opentyl- dimethoxysilane, 4-methylcyclohexyl-3-methylcyclopentyl- diethoxysilane, 4-methylcyclohexyl-3-methylcyclopentyl- dipropoxysilane, 3,5-dimethylcyclohexyl-3-methylcyclopentyl- dimethoxysilane, 3,5-dimethylcyclohexyl-3-methylcyclopentyl- diethoxysilane, 3,5-dimethylcyclohexyl-3-methylcyclopentyl- dipropoxysilane, 3,3-dimethylcyclohexyl-3-methylcyclopentyl- dimethoxysilane, 4,4-dimethylcyclohexyl-3-methylcyclopentyl- dimethoxysilane, cyclohexyl-2,3-dimethyleyelopentyldimethoxy- silane, cyclohexyl-2 3-dimethylcyclopentyldiethoxysilane, cyclohexyl-2,3-dimethylcyclopentyldipropoxysilane, 3-methyl- cyclohexyl-2,3-dimethylcyclopentyldimethoxysilane, 3-methyl- cyclohexyl-2,3-dimethylcyclopentyldiethoxysilane, 3-methyl- cyclohexyl-2 , 3-dimethylcyclopentyldipropoxysilane , 4-methyl- cyclohexyl-2 , 3-dimethylcyclopentyldimethoxysilane, 4-methyl- cyclohexyl-2 , 3-dimethylcyclopentyldiethoxysilane , 4-methyl- cyclohexyl-2 , 3-dimethylcyclopentyldipropoxysilane , 3 , 5- dimethylcyclohexyl-2 , 3-dimethylcyclopentyldimethoxysilane , 3 , 5- dimethylcyclohexyl-2 , 3-dimethylcyclopentyldiethoxysilane, 3 , 5- dimethylcyclohexyl-2 , 3-dimethylcyclopentyldipropoxysilane , 3 , 3- dimethylcyclohexyl-2 , 3-dimethylcyclopentyldimethoxysilane , 4 ,4- dimethylcyclohexyl-2 , 3-dimethylcyclopentyldimethoxysilane , cyclohexyl-2 , 5-dimethylcyclopentyldimethoxysilane, cyclohexyl -
2 , 5-dimethylcyclopentyldiethoxysilane , cyclohexyl-2 , 5-dimethyl- cyclopentyldipropoxysilane , 3-methylcyclohexyl-2 , 5-dimethyl- cyclopentyldimethoxysilane , 3-methylcyclohexyl-2 , 5-dimethyl- cyclopentyldiethoxysilane , 3-methylcyclohexyl-2 , 5-dimethyl- cyclopentyldipropoxysilane, 4-methylcyclohexyl-2 , 5-dimethyl- cyclopentyldimethoxysilane, 4-methylcyclohexyl-2 , 5-dimethyl- cyclopentyldiethoxysilane, 4 -methyl cyclohexyl -2 , 5-dimethyl- cyclopentyldipropoxysilane , 3 , 5-dimethylcyclohexyl-2 , 5- dimethylcyclopentyldimethoxysilane , 3 , 5-dimethylcyclohexyl-2 , 5- dimethylcyclopentyldiethoxysilane , 3 , 5-dimethylcyclohexyl-2 , 5- dimethylcyclopentyldipropoxysilane , 3 , 3-dimethylcyclohexyl-2 , 5- dimethylcyclopentyldimethoxysilane , 4 , 4-dimethylcyclohexyl-2 , 5- dimethylcyclopentyldimethoxysilane, cyclohexyl-2 , 2-dimethyl- cyclopentyldimethoxysilane , cyclohexyl-2 , 2-dimethylcyclopentyl- diethoxysilane , cyclohexyl-2 , 2-dimethylcyclopentyldipropoxy- silane, 3-methylcyclohexyl-2 , 2-dimethylcyclopentyldimethoxy- silane , 3-methylcyclohexyl-2 , 2-dimethylcyclopentyldiethoxy- silane , 3-methylcyclohexyl-2 , 2-dimethylcyclopentyldipropoxy- silane , 4-methylcyclohexyl-2 , 2-dimethylcyclopentyldimethoxy- silane , 4-methylcyclohexyl-2 , 2-dimethylcyclopentyldiethoxy- silane , 4-methylcyclohexyl-2 , 2-dimethylcyclopentyldipropoxy- silane , 3 , 5-dimethylcyclohexyl-2 , 2-dimethylcyclopentyl- dimethoxysilane, 3 , 5-dimethylcyclohexyl-2 , 2-dimethylcyclo- pentyldiethoxysilane , 3 , 5-dimethylcyclohexyl-2 , 2-dimethyl- cyclppentyldipropoxysilane , 3 , 3-dimethylcyclohexyl-2 , 2- dimethylcyclopentyldimethoxysilane , 4 , 4-dimethylcyclohexyl-2 , 2- dimethylcyclopentyldimethoxysilane , cyclohexyl-3 , 3-dimethyl - cyclopentyldimethoxysilane, cyclohexyl-3 , 3-dimethyl cyclopentyl - diethoxysilane , cyclohexyl-3 , 3-dimethyl cyclopentyldipropoxy- silane, 3-methylcyclohexyl-3 , 3-dimethylcyclopentyldimethoxy- silane , 3 -methyl cyclohexyl -3 , 3-dimethyl cyclopentyldiethoxy- silane, 3-methylcyclohexyl-3 , 3 -dimethyl eye lopentyldipropoxy- silane , 4-methylcyclohexyl-3 , 3-dimethylcyclopentyldimethoxy- silane , 4-methylcyclohexyl-3 , 3-dimethylcyclopentyldiethoxy- silane , 4-methylcyclohexyl-3 , 3-dimethylcyclopentyldipropoxy- silane , 3 , 5-dimethylcyclohexyl-3 , 3-dimethylcyclopentyl- dimethoxysilane , 3 , 5-dimethylcyclohexyl-3 , 3-dimethylcyclo- pentyldiethoxysilane , 3 , 5-dimethylcyclohexyl-3 , 3-dimethyl- cyclopentyldipropoxysilane , 3 , 3-dimethylcyclohexyl-3 , 3- dimethylcyclopentyldimethoxysilane , 4 , 4-dimethylcyclohexyl-3 , 3- dimethylcyclopentyldimethoxysilane , 3-chlorocyclohexyl- cyclopentyldimethoxysilane , 4-chlorocyclohexylcyclopentyl- dimethoxysilane, 3 , 5-dichlorocyclohexyl cyclopentyldimethoxy¬ silane , cyclohexyl-2-chlorocyclopentyldimethoxysilane , cyclohexyl-3-cyclopentyldimethoxysilane , cyclohexyl-2 , 3- dichlorocyclopentyldi'methoxysilane , cyclohexyl-2 , 5-dichloro- cyclopentyldimethoxysilane, 3-chlorocyclohexyl-2-chlorocyclo- pentyldimethoxysilane,4-chlorocyclohexyl-3-chlorocyclopentyl- dimethoxysilane, and 3,5-dichlorocyclohexyl-2,3-dichloro- cyclopentyldimethoxysilane. Preferred of these asymmetric organosilicon compounds are., cyclohexylcyclopentyldimethoxysilane, cyclohexylcyclo- pentyldiethoxysilane, 3-methylcyclohexylcyclopentyldimethoxy- silane, 4-methylcyclohexylcyclopentyldimethoxysilane, and 3,5- dimethylcyclohexylcyclopentyldimethoxysilane. These organosilicon compounds may be used either individually or in combination of two or more thereof.
The organosilicon compound of the present invention is useful as an (internal and/or external) electron donor for various olefin polymerization catalysts. Namely, the organosilicon compound can be used as an electron donor in the homo- or copolymerization of ethylene, propylene, 1-butene, 1- pentene, 4-methyl-l-pentene, vinylcyclohexane, etc. In particular, the organosilicon compound is suitable for use as an electron donor of a catalyst for the homopolymerization of ethylene or propylene or the copolymerization of ethylene and propylene, and the optimal use thereof is as an electron donor of a catalyst for the homopolymerization of propylene or the copolymerization of propylene and ethylene.
The cyclohexylcyclopentyldialkoxysilane of the present invention can be prepared by various methods. In one of the simplest methods, the organosilicon compound is obtained by the reaction of a monocycloalkyltrialkoxysilane (i.e., monocyclo- hexyl- or monocyclopentyl-trialkoxysilane) with a cycloalkyl Grignard reagent (i.e., a Grignard reagent having a cyclopentyl or cyclohexyl group, respectively) .
For example, cyclopentyl chloride (commercial product) is first reacted with magnesium in the presence of a solvent, e.g., an ether such as tetrahydrofuran, diethyl ether, or di-n- butyl ether, to yield a cyclopentyl Grignard reagent (cyclo- pentylmagnesium chloride) . This reaction may be carried out at a temperature of from room temperature to 60°C. The cyclo¬ pentyl Grignard reagent is then reacted with cyclohexyltri- methoxysilane to obtain cyclohexylcyclopentyldimethoxysilane; this reaction may be conducted in the presence of an ether such as tetrahydrofuran, diethyl ether, or di-n-butyl ether as in the above-described first reaction, or in the presence of an aliphatic hydrocarbon solvent such as hexane or heptane or an aromatic hydrocarbon solvent such as toluene, benzene, or xylene. This reaction may be carried out at a temperature of from 50°C to 200°C, preferably at a temperature of from 100°C to 200°C or at a temperature of from 100°C to 200°C under boiling or refluxing of the solvent. Although the monocycloalkyltrialkoxysilane, e.g., cyclohexyltrimethoxysilane employed above, for use in the above reaction may be a commercial product, it may be prepared by various known methods. In one method, the desired compound is prepared by reacting cyclohexyltrichlorosilane with methanol to alkoxylate the silane compound with the evolution of hydrogen chloride. Although the cyclohexyltrichlorosilane for use in this reaction may be a commercial product, it may be easily prepared by the hydrosilylation reaction of cyclohexene with trichlorosilane (HSiCl3). Another method for preparing cyclohexyltrimethoxysilane comprises hydrogenating a commercial product of phenyltrimethoxysilane in the presence of a catalyst, e.g., a Raney nickel catalyst. The cyclohexylcyclopentyldimethoxysilane thus produced can be identified by nuclear magnetic resonance spectroscopy ^H-NMR, 13C-NMR), infrared absorption spectrometry (IR), mass spectrometry (MS), etc. 13C-NMR spectrometry (in CDC13) gives a spectrum which has a signal at δ = 50.7 attributable to the carbon atoms of the methoxy groups, signals at 6 = 24.5, 26.8, 26.9, and 27.8 attributable to the cyclohexyl group, and signals at δ = 22.8, 26.7, and 27.4 attributable to the cyclopentyl group. IR spectrometry gives a spectrum having a peak at around 1,100 cm"1 attributable to the Si-O-C bonds. The organosilicon compound of the present invention, i.e., a cyclohexylcyclopentyldialkoxysilane, when used as an electron donor serving as one component of a Ziegler-Natta catalyst for olefin polymerization, makes it possible to obtain a polyolefin having a broad molecular weight distribution and high crystallinity while retaining high performances with respect to catalytic activity and the yield of highly stereoregular polymer which performances are not lower than those conventionally known as high-performance catalysts.
The Ziegler-Natta catalyst of the present invention is not particularly limited as long as the organosilicon compound of formula (I) is contained as an internal or external electron donor, and any conventional components for the Ziegler-Natta catalyst can be used together with the organosilicon compound. In a preferred embodiment of the present invention, the Ziegler-Natta catalyst comprises (A) a solid catalyst component essentially comprising magnesium, titanium, an electron donor compound, and a halogen which is prepared by contacting a magnesium compound, a titanium halide compound, and an internal electron donor compound, (B) an organoaluminum compound, and (C) the organosilicon compound of formula (I) as an external electron donor.
The magnesium compound which can be used for preparing solid catalyst component (A) includes metallic magnesium, a magnesium dihalide, a dialkylmagnesium, an alkylmagnesium halide, a dialkoxymagnesium, a diaryloxymagnesium, and an alkoxymagnesium halide. The alkyl or alkoxy moiety of the above-described magnesium compounds generally has from 1 to 6 carbon atoms and preferably from 1 to 4 carbon atoms.
Specific examples of the magnesium halide are magnesium dichloride, magnesium dibromide, magnesium diiodide, and magnesium difluoride.
Specific examples of the dialkylmagnesium are dimethyl- magnesium, diethylmagnesium, ethylmethylmagnesium, dipropyl- magnesium, methylpropylmagnesium, ethylpropylmagnesium, dibutylmagnesium, butylmethylmagnesium, and butylethyl- magnesium. These dialkylmagnesiums may be obtained by reacting metallic magnesium with a halogenated hydrocarbon or an alcohol.
Specific examples of the alkylmagnesium halide include ethylmagnesium chloride, propylmagnesium chloride, and butyl- magnesium chloride. These alkylmagnesium halides may be obtained by reacting metallic magnesium with a halogenated hydrocarbon or an alcohol.
Specific examples of the dialkoxymagnesium and the diaryloxymagnesium include dimethoxymagnesium, diethoxy- magnesium, dipropoxymagnesium, dibutoxymagnesium, diphenoxy- magnesium, ethoxymethoxymagnesium, ethoxypropoxymagnesium, and butoxyethoxymagnesiu .
Specific examples of the alkoxymagnesium halide are methoxymagnesium chloride, ethoxymagnesium chloride, propoxy- magnesium chloride, and butoxymagnesium chloride.
Preferred of these magnesium compounds are dialkoxy- magnesiums, with diethoxymagnesium and dipropoxymagnesium being especially preferred. The magnesium compounds may be used either individually or in combination of two or more thereof. The dialkoxymagnesium, which can be used preferably, is at least one dialkoxymagnesium species having from 1 to 3 carbon atoms in the alkoxy moiety thereof and has a granular or powdered form, the particles of which may have an irregular shape or a spherical shape. In using spherical particles of diethoxymagnesium, the resulting powdered polymer will have a more satisfactory particle shape and a narrower particle size distribution. As a result, the polymer powder as produced has improved handling properties, and troubles attributed to fine particles, such as obstruction, would be eliminated. The spherical diethoxymagnesium particles as above referred to do not necessarily need to be true spheres, and ellipsoidal or potato-like particles may also be used. The terminology "spherical" as used herein may be quantified as a longer axis diameter ( Q ) to shorter axis diameter (w) ratio ({/w) of not more than 3, preferably from 1 to 2, and still preferably from 1 to 1.5.
The dialkoxymagnesium to be used has an average particle size of from 1 to 200 μm, preferably from 5 to 150 μm.
In the case of spherical diethoxymagnesium, it has an average particle size of from 1 to 100 μm, preferably from 5 to
50 μm, more preferably from 10 to 40 μm. It is preferable to use particles having a sharp size distribution with a small proportion of fine or coarse particles. More specifically, particles containing not more than 20%, preferably not more than 10%, of fine particles of 5 μm or smaller and not more than 10%, preferably not more than 5%, of coarse particles of 100 μm or greater. Such a particle size distribution corresponds to In (D90/D10) of not more than 3, preferably not more than 2, wherein D90 and D10 represent a cumulative 90% diameter and a cumulative 10% diameter, respectively, of a cumulative particle size distribution depicted from the small diameter side. The above-mentioned dialkoxymagnesium does not always need to be present as a starting material in the preparation of solid catalyst component (A) . For example, it may be prepared in situ from metallic magnesium and an alcohol in the presence of a catalyst, e.g., iodine at the time of preparing solid catalyst component (A) .
The titanium halide compound which can be used for preparing solid catalyst component (A) is at least one of a titanium halide and an alkoxytitanium halide represented by formula: Ti(OR5)nXή.n, wherein R5 represents an alkyl group having from 1 to 4 carbon atoms; X represents a chlorine atom, a bromine atom or an iodine atom; and n represents 0 or an integer of 1, 2 or 3. Specific examples of the titanium halide include titanium tetrahalides, such as TiC<!4, TiBr4, and Til4. Specific examples of the alkoxytitanium halide are Ti(OCH3)C{3, Ti(OC2H5)C«3, Ti(OC3H7)C{3, Ti(On-C4H9)C{3, Ti(OCH3) 2CH 2, Ti(OC2H5)2C{2, Ti(OC3H7)2C{2, Ti(On-C4H9)2C{2, Ti(OCH3)3C{ , Ti(OC2H5)3C{ , Ti(OC3H7)3C0 , and Ti(On-CAH9)3CC . Preferred of these titanium halide compounds are titanium tetrahalides, with TiCfl4 being particularly preferred. These titanium halide compounds may be used either individually or in combination of two or more thereof. The electron donor compound which can be used for preparing solid catalyst component (A) is an organic compound containing oxygen or nitrogen. Such a compound include alcohols, phenols, ethers, esters, ketones, acid halides, aldehydes, amines, amides, nitriles, isocyanates, and organo- silicon compounds containing an Si-O-C bond.
Specific examples of the electron donor compound include alcohols, such as methanol, ethanol, propanol, butanol, pentanol, hexanol, octanol, 2-ethylhexyl alcohol, and dodecanol; phenols, such as phenol and cresol; ethers, such as dimethyl ether, diethyl ether, dipropyl ether, dibutyl ether, diamyl ether, and diphenyl ether; monocarboxylic acid esters, such as methyl formate, ethyl acetate, vinyl acetate, propyl acetate, octyl acetate, cyclohexyl acetate, ethyl propionate, ethyl butyrate, methyl benzoate, ethyl benzoate, propyl benzoate, butyl benzoate, octyl benzoate, cyclohexyl benzoate, phenyl benzoate, methyl p-toluylate, ethyl p-toluylate, methyl anisate, and ethyl anisate; dicarboxylic acid esters, such as diethyl maleate, dibutyl maleate, dimethyl adipate, diethyl adipate, dipropyl adipate, dibutyl adipate, dimethyl adipate, diisodecyl adipate, dioctyl adipate, dimethyl phthalate, diethyl phthalate, dipropyl phthalate, dibutyl phthalate, dipentyl phthalate, dihexyl phthalate, diheptyl phthalate, dioctyl phthalate, dinonyl phthalate, and didecyl phthalate; ketones, such as acetone, methyl ethyl ketone, methyl butyl ketone, acetophenone, and benzophenone; acid halides, such as phthalic acid dichloride and terephthalic acid dichloride; aldehydes, such as acetaldehyde, propionaldehyde, octylalde- hyde, and benzaldehyde; amines, such as methylamine, ethyl- amine, tributylamine, piperidine, aniline, and pyridine; amides, such as acetamide, and acrylamide; nitriles, such as acetonitrile, benzonitrile, and tolunitrile; and isocyanates, such as phenyl isocyanate, and n-butyl isocyanate.
Specific examples of the organosilicon compound containing an Si-O-C bond are trimethylmethoxysilane, trim- ethylethoxysilane, tri-n-propylmethoxysilane, tri-n-propyl- ethoxysilane, tri-n-butylmethoxysilane, tri-isobutylmethoxy- silane, tri-t-butylmethoxysilane, tri-n-butylethoxysilane, tricyclohexylmethoxysilane, tricyclohexylethoxysilane, dimethyldimethoxysilane, dimethyldiethoxysilane, di-n-propyl- dimethoxysilane, diisopropyldimethoxysilane, di-n-propyl- diethoxysilane, diisopropyldiethoxysilane, di-n-butyldimethoxy- silane, diisobutyldimethoxysilane, di-t-butyldimethoxysilane, di-n-butyldiethoxysilane, n-butylmethyldimethoxysilane, bis(2- ethylhexyl)dimethoxysilane, bis(2-ethylhexyl)diethoxysilane, dicyclohexyldimethoxysilane, dicyclohexyldiethoxysilane, dicyclopentyldimethoxysilane, dicyclopentyldiethoxysilane, eyelohexylmethyldimethoxysilane, cyclohexylmethyldiethoxy- silane, cyclohexylethyldimethoxysilane, cyclohexylisopropyl- dimethoxysilane, cyclohexylethyldiethoxysilane, cyclopentyl- methyldimethoxysilane, cyclopentylethyldiethoxysilane, cyclo- pentylisopropyldimethoxysilane,cyclohexyl(n-pentyl)dimethoxy¬ silane, cyclopentylisobutyldimethoxysilane, diphenyldimethoxy- silane, diphenyldiethoxysilane, phenylmethyldimethoxysilane, phenylmethyldiethoxysilane, phenylethyldimethoxysilane, phenyl- ethyldiethoxysilane, cyclohexyldimethylmethoxysilane, cyclo- hexyldimethylethoxysilane, eyelohexyldiethylmethoxysilane, cyclohexyldiethylethoxysilane, 2-ethylhexyltrimethoxysilane, 2- ethylhexyltriethoxysilane,cyclohexyl(n-pentyl)diethoxysilane, cyclopentylmethyldimethoxysilane, cyclopentylethyldimethoxy- silane, cyclopentylmethyldiethoxysilane, cyclopentylethyl¬ diethoxysilane, cyclohexyl(n-propyl)dimethoxysilane, cyclo¬ hexyl(n-butyl)dimethoxysilane, cyclohexyl(n-propyl)diethoxy¬ silane, cyclohexyl(n-butyl)diethoxysilane, methyltrimethoxy- silane, methyltriethoxysilane, ethyltrimethoxysilane, ethyl- triethoxysilane, n-propyltrimethoxysilane, n-propyltriethoxy- silane, isopropyltrimethoxysilane, isopropyltriethoxysilane, n- butyltrimethoxysilane, isobutyltrimethoxysilane, t-butyl- trimethoxysilane, n-butyltriethoxysilane, cyclohexyltrimethoxy- silane, cyclohexyltriethoxysilane, cyclopentyltrimethoxysilane, cyclopentyltriethoxysilane, vinyltrimethoxysilane, vinyl- triethoxysilane, 2-ethylhexyltrimethoxysilane, 2-ethylhexyl- triethoxysilane, phenyltrimethoxysilane, and phenyltriethoxy- silane.
Among these electron donor compounds preferred are esters, with phthalic diesters being more preferred. The ester moiety in the phthalic diesters is preferably a straight chain or branched chain alkyl group having from 1 to 12 carbon atoms and preferably from 2 to 10 carbon atoms. Specific examples of suitable phthalic diesters are dimethyl phthalate, diethyl phthalate, di-n-propyl phthalate, diisopropyl phthalate, di-n- butyl phthalate, diisobutyl phthalate, ethyl ethyl phthalate, methylisopropyl phthalate, ethyl-n-propyl phthalate, ethyl-n- butyl phthalate, di-n-pentyl phthalate, diisopentyl phthalate, dihexyl phthalate, di-n-heptyl phthalate, di-n-octyl phthalate, bis(2-methylhexyl)phthalate, bis(2-ethylhexyl) phthalate, di-n- nonyl phthalate, diisodecyl phthalate, bis(2,2-dimethylheptyl) phthalate, n-butylisohexyl phthalate, n-butylisooctyl phthalate, n-pentylhexyl phthalate, n-pentylisohexyl phthalate, isopentylheptyl phthalate, n-pentylisooctyl phthalate, n- pentylisononyl phthalate, isopentyl-n-decyl phthalate, n- pentylundecyl phthalate, isopentylisohexyl phthalate, n- hexylisooctyl phthalate, n-hexylisononyl phthalate, n-hexyl-n- decyl phthalate, n-heptylisooctyl phthalate, n-heptylisononyl phthalate, n-heptylneodecyl phthalate, and isooctylisononyl phthalate. These phthalic acid esters may be used either individually or in combination of two or more thereof. The preferred combination of the phthalic acid esters is exemplified with: diethyl phthalate and bis(2-ethylhexyl) phthalate; di-n-butyl phthalate and bis(2-ethylhexyl) phthalate; diisobutyl phthalate and bis(2-ethylhexyl) phthalate; and diethyl phthalate, bis(2-ethylhexyl) phthalate and di-n-butyl phthalate.
Solid catalyst component (A) can be prepared by contacting the above-mentioned magnesium compound, titanium halide compound and electron donor compound in a manner appropriately selected from conventional means. Known methods for preparing a solid catalyst component are disclosed, e.g., in JP-A-63-308004, JP-A-63-314211, JP-A-64-6006, JP-A-64-14210, JP-A-64-43506, JP-A-63-3010, and JP-A-62-158704.
Typical methods for preparing solid catalyst component (A) are described below.
(1) Magnesium chloride is dissolved in a tetraalkoxy- titanium, and the solution is brought into contact with polysiloxane to obtain a solid component. The solid component is reacted with silicon tetrachloride, contacted with phthalic acid dichloride, and reacted with titanium tetrachloride to prepare solid catalyst component (A) . The resulting solid catalyst component may be preliminarily treated with an organo¬ aluminum compound, an organosilicon compound, and an olefin.
(2) Anhydrous magnesium chloride and 2-ethylhexyl alcohol are reacted to form a uniform solution, which is brought into contact with phthalic anhydride. The resulting solution is then brought into contact with titanium tetrachloride and diester of phthalic acid to obtain a solid component, which is further reacted with titanium tetrachloride to prepare solid catalyst component (A) .
(3) Metallic magnesium, butyl chloride, and butyl ether are reacted to synthesize an organomagnesiu compound. The organo- magnesium compound is brought into contact with tetrabutoxy- titanium and tetraethoxysilane to obtain a solid product, which is then brought into contact with a diester (e.g., an alkyl ester having 1 to 10 carbon atoms) of phthalic acid, dibutyl ether, and titanium tetrachloride to prepare solid catalyst component (A) . The resulting solid catalyst component may be preliminarily treated with an organoaluminum compound, an organosilicon compound, and an olefin.
(4) An organomagnesium compound, e.g., dibutylmagnesium, and an organoaluminum compound are brought into contact with an alcohol, e.g., butanol or 2-ethylhexyl alcohol, in the presence of a hydrocarbon solvent to form a uniform solution. The resulting solution is brought into contact with a silicon compound, e.g., SiC{4, HSiC03 or polysiloxane, to obtain a solid component. The solid component is brought into contact with titanium tetrachloride and a diester of phthalic acid in the presence of an aromatic hydrocarbon solvent, and the reaction mixture is further brought into contact with titanium tetra¬ chloride to obtain solid catalyst component (A) .
(5) Magnesium chloride, a tetraalkoxytitanium, and an aliphatic alcohol are brought into contact in the presence of an aliphatic hydrocarbon to form a uniform solution. Titanium tetrachloride is added to the solution, and the mixture is heated to precipitate a solid component. The solid component is contacted with a diester of phthalic acid and further reacted with titanium tetrachloride to prepare solid catalyst component (A) .
(6) Metallic magnesium powder, an alkyl monohalide, and iodine are contacted. The resulting reaction product, a tetra- alkoxytitanium, an acid halide, and an aliphatic alcohol are contacted in the presence of an aliphatic hydrocarbon to form a uniform solution. Titanium tetrachloride is added to the solution, and the mixture is heated to precipitate a solid component. The solid component is brought into contact with a diester of phthalic acid and further reacted with titanium tetrachloride to prepare solid catalyst component (A) .
(7) Diethoxymagnesium is suspended in an alkylbenzene or a halogenated hydrocarbon solvent, and the resulting suspension is brought into contact with titanium tetrachloride. The mixture is heated and then contacted with a diester (e.g., an alkyl ester having 1 to 10 carbon atoms) of phthalic acid to obtain a solid component. The solid component is washed with an alkylbenzene and again contacted with titanium tetrachloride in the presence of the alkylbenzene to prepare solid catalyst component (A) . The resulting solid catalyst component may be subjected to a heat treatment in the presence or absence of a hydrocarbon solvent.
(8) Diethoxymagnesium is suspended in an alkylbenzene, and the resulting suspension is brought into contact with titanium tetrachloride and phthalic acid chloride to obtain a solid component. The solid component is washed with an alkylbenzene and again contacted with titanium tetrachloride in the presence of the alkylbenzene to prepare solid catalyst component (A) . The resulting solid catalyst component may further be contacted with titanium tetrachloride twice or more times.
(9) Diethoxymagnesium, calcium chloride, and a silicon compound represented by Si(OR6)4 (wherein R6 is an alkyl group or an aryl group) are co-ground, and the resulting grinds are suspended in an aromatic hydrocarbon. The suspension is brought into contact with titanium tetrachloride and an diester (e.g., an alkyl ester having 1 to 10 carbon atoms) of phthalic acid, and the product is further contacted with titanium tetra¬ chloride to prepare solid catalyst component (A) .
(10) Diethoxymagnesium and a diester of phthalic acid are suspended in an alkylbenzene, and the suspension is added to titanium tetrachloride to obtain a solid component. The solid component is washed with an alkylbenzene, and further contacted with titanium tetrachloride in the presence of the alkylbenzene to prepare solid catalyst component (A) .
(11) A calcium halide and aliphatic magnesium, e.g., magnesium stearate, are contact reacted with titanium tetrachloride and a diester (e.g., an alkyl ester having 1 to 10 carbon atoms) of phthalic acid, and the reaction product is further brought into contact with titanium tetrachloride to prepare solid catalyst component (A) .
(12) Diethoxymagnesium is suspended in an alkylbenzene or a halogenated hydrocarbon solvent, and the resulting suspension is brought into contact with titanium tetrachloride, and the mixture is heated and contacted with a diester (e.g., an alkyl ester having 1 to 10 carbon atoms) of phthalic acid to react. The resulting solid component is washed with an alkylbenzene and further contacted with titanium tetrachloride in the presence of the alkylbenzene to prepare solid catalyst component (A) . At any stage of the above preparation procedure, the system may be brought into contact with aluminum chloride.
(13) Diethoxymagnesium is suspended in an alkylbenzene or a halogenated hydrocarbon solvent, and the resulting suspension is brought into contact with titanium tetrachloride, and the mixture is heated and contacted with two or more diesters of phthalic acid different in the carbon atom number of the alkyl moiety (e.g., diethyl phthalate and bis(2-ethyhexyl) phthalate) to obtain a solid component. The resulting solid component is washed with an alkylbenzene and further contacted with titanium tetrachloride in the presence of the alkylbenzene to prepare solid catalyst component (A) . In the above preparation, when the solid component is brought into contact with titanium tetrachloride, it may again contacted with two or more diesters of phthalic acid different in the carbon atom number of the alkyl moiety. Further, the diesters of phthalic acid may be used in combination with the above-enumerated electron donor compound other than diesters of phthalic acid.
(14) Diethoxymagnesium, titanium tetrachloride, and a diester of phthalic acid are brought into contact in the presence of chlorobenzene, and the reaction product is then contacted with titanium tetrachloride and phthalic acid dichloride. The product is further contact reacted with titanium tetrachloride to prepare solid catalyst component (A) . The thus prepared solid catalyst component may further be contacted with titanium tetrachloride. Further, at any stage of the above preparation procedure, a silicon compound may be contacted with the preparation system. (15) Diethoxymagnesium, 2-ethylhexyl alcohol, and carbon dioxide are brought into contact in the presence of toluene to form a uniform solution. The solution is contacted with titanium tetrachloride and a diester of phthalic acid to obtain a solid component. The solid component is dissolved in tetrahydrofuran, and the solid component is made to precipitate. The resulting solid component is contact reacted with titanium tetrachloride to prepare solid catalyst component. If desired, the contact with titanium tetrachloride may be conducted repeatedly. At any stage of the above preparation procedure, a silicon compound, e.g., tetrabutoxy- silane, may be contacted with the preparation system.
The amounts of the magnesium compound, titanium halide compound and electron donor compound to be used for the preparation of solid catalyst component (A) vary depending on the method of preparation and cannot be generally specified. For example, the titanium halide compound is used in an amount of from 0.5 to 100 mol, preferably from 1 to 10 mol, and the electron donor compound from 0.01 to 3 mol, preferably from 0.02 to 1 mol, each per mole of the magnesium compound. The titanium content in solid catalyst component (A) is not particularly limited and it is generally from 0.5 to 10 % by weight, preferably from 1 to 5 % by weight, based on the weight of solid catalyst component (A) . Organoaluminum compound (B) which can be used in the present invention includes compounds represented by general formula: R7 yAlY3_y, wherein R7 represents an alkyl group having from 1 to 4 carbon atoms; Y represents a hydrogen atom, a chlorine atom, a bromine atom or an iodine atom; and y represents an integer of 1, 2 or 3.
Specific examples of organoaluminum compound (B) are triethylaluminum, diethylaluminum chloride, triisobutyl- aluminum, diethylaluminum bromide, and diethylaluminum hydride. These organoaluminum compounds may be used either individually or in combination of two or more thereof. Preferred of them are triethylaluminum and triisobutylaluminum.
Organosilicon compound (C) which is preferably used in the present invention includes compounds represented by formula (I).
A combined use of the specific organosilicon compound (C) with solid catalyst component (A) and organoaluminum compound (B) makes it possible to produce an olefin polymer having markedly higher stereoregularity and broader molecular weight distribution in higher yield than in using conventional catalysts.
In the present invention, an olefin is homo- or copolymerized in the presence of the Ziegler-Natta catalyst comprising solid catalyst component (A) , organoaluminum compound (B), and organosilicon compound (C). The ratio of components (A), (B), and (C) to be used is not particularly limited as long as the effects of the present invention are not impaired. Usually, organoaluminum compound (B) is used in an amount of from 1 to 500 mol and preferably from 5 to 400 mol per mol of the titanium atom in solid catalyst component (A), and organosilicon compound (C) is used in an amount of from 0.0020 to 2 mol and preferably from 0.0025 to 0.5 mol per mol of organoaluminium compound (B) .
The Ziegler-Natta catalyst of the present invention can be prepared by bringing the above-described components (A), (B) and (C) into contact. There is no particular limitation on the order in contact of the components (A), (B) and (C). In general, the component (B) is brought into contact with the component (C) and subsequently with the component (A), or the component (B) is brought into contact with the component (A) and subsequently with the component (C).
Recommended combinations of the components (A), (B), and (C) are tabulated in Table 1 below.
TABLE 1
Solid Catalyst Component (A) Organo¬ (Process of aluminum Organosilicon Preparation ) Compound (B ) Compound (C ) process (7) triethyl¬ cyclohexylcyclopentyl- aluminum dimethoxysilane process (7) triethyl¬ 3-methyleye1ohexy1- aluminum eyelopentyldimethoxysilane process (8) triethyl¬ eye1ohexy1eye1openty1- aluminum dimethoxysilane process (10) triethyl¬ eyelohexyleyelopentyl- aluminum dimethoxysilane process (10) triethyl¬ 4-methyleye1ohexy1- aluminum cyclopentyldimethoxysilane process (12) triethyl¬ cyclohexylcyclopentyl- aluminum dimethoxysilane process (12) triethyl¬ 3-methylcyclohexylcyclo- aluminum pentyldimethoxysilane process (13) triethyl¬ eyelohexylcyclopentyl- aluminum dimethoxysilane Process (13) triethyl¬ 3,5-dimethylcyclohexyl- aluminum cyclopentyldimethoxysilane
Polymerization reaction according to the present invention may be carried out in the presence or absence of an organic solvent. The olefin monomer to be polymerized may be used in either a gaseous state or a liquid state. The polymerization is conducted at a temperature of not higher than 200°C, preferably not higher than 100°C, under a pressure of not higher than 10 MPa, preferably not higher than 5 MPa. The reaction may be effected either in a continuous system or in a batch system and through one step or two or more steps. The olefins to be homo- or copolymerized according to the present invention are not particularly limited and generally have 2 to 20 carbon atoms, such as ethylene, propylene, 1-butene, 1-pentene, 4-methyl-l-pentene, and vinyl- cyclohexane. These olefins may be used either individually or in combination of two or more thereof. The effects of the present invention in assuring high stereoregularity, broad molecular weight distribution, and high yield are particularly pronounced in homopolymerization of propylene or copolymeriza- tion of propylene and ethylene.
For ensuring the improvements in catalytic activity and stereoregularity and particle properties of the polymer produced, it is preferable to conduct pre-polymerization prior to substantial polymerization. Monomers to be pre-polymerized include not only ethylene and propylene but other monomers, such as styrene and vinylcyclohexane.
The catalyst of the present invention is used in an amount of about 0.005 to 0.5 mmol, preferably about 0.01 to 0.5 mmol, calculated as titanium atom in solid catalyst component (A) per liter of the polymerization zone.
According to the process of the present invention, the olefin polymers obtained have a broader molecular weight distribution than those obtained by conventional processes, by at least 1 higher as expressed in terms of the ratio of weight average molecular weight to number average molecular weight (Mw/Mn) of the olefin polymers, and the yield of stereoregular polymers is extremely high. That is, the process has been confirmed to provide polyolefins having not only broad molecular weight distribution (for example, 6 or higher in terms of the Mw/Mn) but high stereoregularity in extremely high yield.
The present invention will now be illustrated in greater detail with reference to Examples in view of Comparative Examples, but it should be understood that the present invention is not construed as being limited to these Examples. All the percents are by weight unless otherwise indicated. EXAMPLE 1
Preparation of Cyclohexylcyclopentyldimethoxysilane:
Into a 2-liter four-necked flask equipped with a stirrer, thermometer, Dimroth condenser, and dropping funnel was introduced 18.5 g (0.76 mol) of magnesium shavings. The magnesium was dried in an argon stream, and 20 ml of di-n-butyl ether was then added thereto. The contents were cooled to room temperature, and a small amount of 1,2-dibromoethane was added thereto to activate the magnesium. A solution prepared by dissolving 79.6 g (0.76 mol) of cyclopentyl chloride in 600 ml of di-n-butyl ether was then added dropwise over a period of 3.5 hours, during which the temperature of the system spontaneously increased to 50°C. Subsequently, 143.0 g (0.70 mol) of cyclohexyltrimethoxysilane was added thereto at room temperature, and the reaction was then conducted for 1 hour under reflux.
After completion of the reaction, the reaction mixture was cooled to room temperature, and 372 g (0.38 mol) of a 10% aqueous sulfuric acid, solution was added thereto dropwise at a temperature of 40°C or lower. The organic layer was washed with 300 ml of a 1% aqueous sodium hydrogen carbonate solution and then dried over anhydrous magnesium sulfate. After the drying agent was filtered off, vacuum distillation was performed to obtain 143.6 g of a fraction having a boiling point of 78°C at 0.2 Torr. The yield was 84.6%. This reaction product was ascertained to be cyclohexylcyclopentyldimethoxy- silane by MS, two-dimensional analysis with
Figure imgf000035_0001
and IR. The results of MS, -NMR/^C-NMR (COSY spectrum), and IR are shown in Figs. 1, 2, and 3, respectively.
The analyses by MS,
Figure imgf000035_0002
and IR were carried out under the following conditions. MS: apparatus ... Finigan Mat (GC-MS). ^-NMR/^C-NMR: apparatus ... JEOL GSX270, solvent ... CDC13.
IR: apparatus ... Perkin Elmer 1600 Series (FT-IR),
KBr sand method.
EXAMPLE 2 Preparation of Solid Catalyst Component (A-l):
In a 200 m{-volume round flask equipped with a stirrer having been thoroughly purged with nitrogen gas were charged 10 g of diethoxymagnesium and 80 mC of toluene to prepare a suspension. To the suspension was added 20 f of titanium tetrachloride, the mixture was heated to 80°C, at which 2.7 τa. of di-n-butyl phthalate was added. The mixture was further heated up to 110°C, at which the mixture was allowed to react for 2 hours with stirring. After completion of the reaction, the reaction mixture was washed with two 100 md portions of toluene at 90°C, and 20 mfi of titanium tetrachloride and 80 mβ of toluene were added thereto. The mixture was heated to 100°C, at which it was allowed to react for 2 hours while stirring. After completion of the reaction, the reaction mixture was washed with ten 100 mC portions of n-heptane at 40°C to obtain solid catalyst component (A-l). The solid content of solid catalyst component (A-l), separated by solid- liquid separation, was found to have a titanium content of 2.91%.
Preparation of Catalyst System and Polymerization:
In a 2.0 i-volume autoclave equipped with a stirrer having been thoroughly purged with nitrogen gas were charged 1.32 mmol of triethylaluminum, 0.13 mmol of cyclohexylcyclo- pentyldimethoxysilane, and 0.0066 mmol, in terms of titanium atom, of the above prepared solid catalyst component (A-l) to form a catalyst system for polymerization. Then, 1.8 ! of hydrogen gas and 1.4 C of liquefied propylene were charged in the autoclave, and the system was subjected to polymerization at 70°C for 30 minutes. The properties of the resulting polymer are shown in Table 2 below. In Table 2, n-heptane- insoluble content, polymerization activity, yield of total crystalline polymer, and molecular weight distribution were obtained as follows. n-Heptane-Insoluble Content:
The polymer as produced weighing (a) g was extracted with boiling n-heptane for 6 hours, and the weight of the insoluble polymer (referred to (b) g) was measured. Polymerization Activity:
(a)/Weight of solid catalyst component (g) Yield of Total Crystalline Polymer: ((b)/(a)) x 100 (%) Molecular Weight Distribution:
Mw/Mn
Mw: Weight average molecular weight Mn: Number average molecular weight
EXAMPLE 3 Preparation of Solid Catalyst Component (A-2):
In a 200 mt-volume round flask equipped with a stirrer having been thoroughly purged with nitrogen gas were charged 20 m{ of titanium tetrachloride and 30 mC of toluene to prepare a mixed solution. To the mixed solution was added a suspension of 10 g of spherical diethoxymagnesium particles (length/width = 1.1/1; average particle size 30μm; In(D90/D10) = 1.23), 50 ml? of toluene, and 3.6 m{ of di-n-butyl phthalate, and the mixture was heated to 90°C, at which it was allowed to react for 1 hour with stirring. After completion of the reaction, the reaction mixture was washed with two 100 itiC portions of toluene at 90°C, and 20 mf of titanium tetrachloride and 80 mC of toluene were added thereto. The mixture was heated to 110°C, at which it was allowed to react for 2 hours while stirring. After completion of the reaction, the reaction mixture was washed ten 100 mC portions of n-heptane at 40°C to obtain solid catalyst component (A-2). The solid content of catalyst component (A-2), separated by solid-liquid separation, was found to have a titanium content of 2.87%.
Preparation of Catalyst System and Polymerization:
Propylene was polymerized in the same manner as in Example 2, except for using solid catalyst component (A-2). The reaction results are shown in Table 2. EXAMPLE 4
Preparation of Solid Catalyst Component (A-3):
In a 200 mC-volume round flask equipped with a stirrer having been thoroughly purged with nitrogen gas were charged 10 g of diethoxymagnesium and 80 m. of toluene to prepare a suspension. To the suspension was added 20 mβ of titanium tetrachloride, and the mixture was heated to 60°C, at which 1.0 mC of diethyl phthalate was added. The mixture was further heated up to 110°C, at which 2.5 m{ of di-iso-octyl phthalate was added thereto. The mixture was further heated to 112°C, at which the mixture was allowed to react for 1.5 hours with stirring. After completion of the reaction, the reaction mixture was washed with two 100 mC portions of toluene at 90°C, and 20 mC of titanium tetrachloride and 80 m{ of toluene were added thereto. The mixture was heated to 100°C, and it was allowed to react at that temperature for 2 hours while stirring. After completion of the reaction, the reaction mixture was washed with ten 100 mi portions of n-heptane at 40°C to obtain solid catalyst component (A-3). The solid content of solid catalyst component (A-3), separated by solid- liquid separation, was found to have a titanium content of 2.74%. Preparation of Catalyst System and Polymerization: Propylene was polymerized in the same manner as in
Example 2, except for using solid catalyst component (A-3). The reaction results are shown in Table 2.
EXAMPLE 5 Preparation of Solid Catalyst Component (A-4): In a 200 mi-volume round flask equipped with a stirrer having been thoroughly purged with nitrogen gas were charged 10 g of diethoxymagnesium and 80 ml? of toluene to prepare a suspension. To the suspension was added 20 ml! of titanium tetrachloride, and the mixture was heated to 62°C, at which 1.0 mC of diethyl phthalate was added. The mixture was heated up to 110°C, at which 4.0 m? of di-iso-octyl phthalate was added thereto. The mixture was further heated to 112°C, at which the mixture was allowed to react for 1.5 hours with stirring. After completion of the reaction, the reaction mixture was washed with two 100 ml? portions of toluene at 90°C, and 20 mC of titanium tetrachloride and 80 m. of toluene were added thereto. The mixture was heated to 100°C, and it was allowed to react at that temperature for 2 hours while stirring. After completion of the reaction, the reaction mixture was washed with ten 100 mi portions of n-heptane at 40°C to obtain solid catalyst component (A-4). The solid content of solid catalyst component (A-4), separated by solid- liquid separation, was found to have a titanium content of 2.17%. Preparation of Catalyst System and Polymerization:
Propylene was polymerized in the same manner as in Example 2, except for using solid catalyst component (A-4). The reaction results are shown in Table 2.
COMPARATIVE EXAMPLE 1 Propylene was polymerized in the same manner as in Example 2, except for replacing cyclohexylcyclopentyldimethoxy- silane with phenyltriethoxysilane. The reaction results are shown in Table 2.
COMPARATIVE EXAMPLE 2 Propylene was polymerized in the same manner as in Example 2, except for replacing cyclohexylcyclopentyldimethoxy- silane with eyelohexylmethyldimethoxysilane. The reaction results are shown in Table 2.
COMPARATIVE EXAMPLE 3 Propylene was polymerized in the same manner as in Example 2, except for replacing cyclohexylcyclopentyldimethoxy- silane with dicyclopentyldimethoxysilane. The reaction results are shown in Table 2.
EXAMPLE 6 Preparation of Solid Catalyst Component (A-5): In a 200 m{-volume round flask equipped with a stirrer having been thoroughly purged with nitrogen gas were charged 7.14 g of anhydrous magnesium chloride, 37.5 ml? of decane and 35.1 m{ of 2-ethylhexyl alcohol, and the resulting mixture was heated at 130°C for 2 hours to obtain a uniform solution. Then 1.67 g of phthalic anhydride was added thereto, followed by stirring at 130°C for one hour. The thus obtained uniform solution was cooled to room temperature and was dropwise added, over one hour, to 200 mi of titanium tetrachloride which had been cooled at -20°C. After addition of the solution, the temperature of the resulting solution was increased to 110°C over 4 hours, at which 5.03 mi of diisobutyl terephthalate was further added to the solution, and the resulting solution was then stirred for 2 hours to continue the reaction at 110°C. The hot reaction mixture was subjected to filtration to thereby obtain a solid product which was then dispersed in 275 mi of titanium tetrachloride and allowed to stand at 110°C for 2 hours. Thereafter, a solid product was separated again from the dispersion by filtration while the dispersion was hot, and the solid product was washed with decane and heptane at 110°C to obtain solid catalyst component (A-5). The solid content of solid catalyst component (A-5), separated by solid-liquid separation, was found to have a titanium content of 2.06 %. Preparation of Catalyst System and Polymerization: Propylene was polymerized in the same manner as in
Example 2, except for using solid catalyst component (A-5). The reaction results are shown in Table 2.
EXAMPLE 7 Preparation of Solid Catalyst Component (A-6)
In a 250 m -volume round flask equipped with a stirrer having been thoroughly purged with nitrogen gas was charged a solution of 1.4 mi of titanium tetrachloride dissolved in 74 mβof chlorobenzene, and 3.6 m. of diisobutyl phthalate and 11.8 g of diethoxymagnesium were subsequently added thereto. To the resulting solution was further added a solution of 94 mi of titanium tetrachloride dissolved in 24 mi of chlorobenzene. The addition of these compounds and the solution was conducted at a temperature of 20 to 25 °C. The resulting mixture was heated at 110 °C with stirring for one hour, followed by filtration while the mixture was hot. The thus obtained solid product was added to a solution of 94 mi of titanium tetrachloride dissolved in 24 mi of chlorobenzene to form a slurry at room temperature. Then, a solution obtained by dissolving 0.9 g of phthaloyl dichloride in 74 mi of chlorobenzene was added to the slurry at room temperature, followed by heating at 110 °C with stirring for 30 minutes. The resulting mixture was filtered while it was hot, whereby a solid product was obtained.
To the thus obtained solid product was added, at room temperature, a solution of 94 mC of titanium tetrachloride dissolved in 24 mi of chlorobenzene to thereby form a slurry. 74 mi of chlorobenzene was further added, at room temperature, to the slurry which was then heated at 110 °C with stirring for 30 minutes. The resulting mixture was filtered while it was hot, whereby a solid product was obtained. Using the thus obtained solid product, the above procedure was repeated again to obtain a solid product, which was then washed 10 times with 100 mi of heptane at 25 °C. Thus, solid catalyst component (A- 6) was obtained. The solid content thereof, separated by solid-liquid separation, was found to have a titanium content of 2.63 %.
Preparation of Catalyst system and Polymerization:
Propylene was polymerized in the same manner as in Example 2, except for using solid catalyst component (A-6). The reaction results are shown in Table 2. COMPARATIVE EXAMPLE 4
Propylene was polymerized in the same manner as in Example 6, except for replacing cyclohexylcyclopentyldimethoxy- silane with cyclohexylmethyldimethoxysilane. The reaction results are shown in Table 2. COMPARATIVE EXAMPLE 5
Propylene was polymerized in the same manner as in Example 7, except for replacing cyclohexylcyclopentyldimethoxy- silane with cyclohexylmethyldimethoxysilane. The reaction results are shown in Table 2. EXAMPLE 8
Preparation of Solid Catalyst Component:
Into a 200-ml round-bottom flask the inside atmosphere of which had been sufficiently replaced with nitrogen gas and which was equipped with a stirrer were introduced 10 g of diethoxymagnesium and 80 ml of toluene. The contents were stirred to obtain a suspension. To this suspension was added 20 ml of titanium tetrachloride. The mixture was heated and, at the time when the temperature thereof had reached 62°C, 1.0 ml of diethyl phthalate was added. This mixture was then heated and, at the time when the temperature thereof had reached 110°C, 3.5 ml of dioctyl phthalate was added. The resulting mixture was heated to 112°C and stirred at this temperature for 1.5 hours to allow a reaction to proceed. After completion of the reaction, the reaction product was washed twice with 100 ml of toluene heated at 90°C. To the washed reaction product were added 20 ml of titanium tetrachloride and 80 ml of toluene. This mixture was heated to 100°C and stirred for 2 hours to allow a reaction to proceed. After completion of the reaction, the reaction product was washed 10 times with 100 ml of n-heptane warmed at 40°C to obtain a solid catalyst component. The titanium content of this solid catalyst component was measured and found to be 2.46% by weight.
Formation of Polymerization Catalyst and Polymerization of Olefin:
Into a 2.0-liter autoclave the inside atmosphere of which had been sufficiently replaced with nitrogen gas and which was equipped with a stirrer were introduced 1.32 mmol of triethylaluminum, 0.13 mmol of cyclohexylcyclopentyldi- methoxysilane, and 0.0066 mmol of the solid catalyst component in terms of the amount of titanium atoms. Thus, a polymerization catalyst was formed. Thereafter, 1.8 liters of hydrogen gas and 1.4 liters of liquefied propylene were introduced into the autoclave to conduct polymerization at 70°C for 30 minutes. The yield of the wholly crystalline polymer was 98.3%. The polymer yielded had a melting point of 164.0°C. The reaction results are shown in Table 2.
Figure imgf000045_0001
As described above, the organosilicon compound of the present invention, when used as an electron donor serving as one component of an olefin polymerization catalyst, gives a polyolefin having a broad molecular weight distribution and high crystallinity, while retaining high performances with respect to catalytic activity and the yield of highly stereoregular polymer which performances are equal to or higher than those of conventionally known high-performance catalysts. The organosilicon compound therefore is capable of providing at low cost a general-purpose polyolefin excellent in rigidity and moldability. Furthermore, the organosilicon compound of the present invention is expected to be useful as, e.g., a silane coupling agent, a modifier for resins, etc.
Further, the Ziegler-Natta catalyst for olefin polymerization according to the present invention comprises (A) a specific solid catalyst component, (B) an organoaluminum compound, and (C) an asymmetric organosilicon compound containing a cyclohexyl group or a derivative thereof and a cyclopentyl group or a derivative thereof. Polymerization of an olefin in the presence of the catalyst of the present invention provides an olefin polymer having high stereoregularity (high yield of total crystalline polymer) and broad molecular weight distribution in high yield.
While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.

Claims

1. An organosilicon compound represented by formula (I)
OR"!
Figure imgf000048_0001
wherein R1 and R2, which may be the same or different, each represents an alkyl group having from 1 to 3 carbon atoms; R3 and R4, which may be the same or different, each represents an alkyl group having from 1 to 3 carbon atoms, or a halogen atom; and m and n each represents 0 or an integer of 1 or 2.
2. The organosilicon compound as claimed in claim 1, whichis cyclohexylcyclopentyldimethoxysilane, cyclohexylcyclo- pentyldiethoxysilane,cyclohexylcyclopentyldi-n-propoxysilane, or cyclohexylcyclopentyldiisopropoxysilane.
3. A Ziegler-Natta catalyst for the. polymerization of olefins comprising (A) a solid catalyst component essentially containing magnesium, titanium, an electron donor compound, and a halogen which is prepared by bringing a magnesium compound, a titanium halide compound, and an electron donor compound into contact, (B) an organoaluminum compound, and (C) an organosilicon compound represented by formula (I) : OR1
Figure imgf000049_0001
wherein R1 and R2, which may be the same or different, each represents an alkyl group having from 1 :-to 3 carbon atoms; R3 and R4, which may be the same or different, each represents an alkyl group having from 1 to 3 carbon atoms, or a halogen atom; and m and n each represents 0 or an integer of 1 or 2.
4. The catalyst for the polymerization of olefins as claimed in claim 3, wherein said magnesium compound used in preparation of solid catalyst component (A) is a dialkoxymagnesium.
5. The catalyst for the polymerization of olefins as claimed in claim 3, wherein said magnesium compound used in preparation of solid catalyst component (A) is diethoxymagnesiu .
6. The catalyst for the polymerization of olefins as claimed in claim 3, wherein said magnesium compound used in preparation of solid catalyst component (A) is diethoxymagnesium in the form of spherical particles.
7. The catalyst for the polymerization of olefins as claimed in claim 3, wherein said titanium halide compound used in preparation of solid catalyst component (A) is a titanium halide or alkoxytitanium halide, represented by formula Ti(OR5)nX4.n, wherein R5 represents an alkyl group having from 1 to 4 carbon atoms, X represents a chlorine atom, a bromide atom or an iodine atom, and n is 0 or an integer of 1, 2 or 3.
8. The catalyst for the polymerization of olefins as claimed in claim 3, wherein said electron donor compound used in preparation of solid catalyst component (A) is a diester of phthalic acid, the ester moieties thereof being an alkyl group having 1 to 10 carbon atoms.
9. The catalyst for the polymerization of olefins as claimed in claim 3, wherein said organoaluminium compound (B) is represented by formula R7yAlY3_y, wherein R7 represents an alkyl group having from 1 to 4 carbon atoms, Y represents a hydrogen atom, a chlorine atom, a bromine atom, or an iodine atom, and y represents an integer of 1, 2 or 3.
10. The catalyst for the polymerization of olefins as claimed in claim 3, wherein said organosilicon compound (C) is at least one compound selected from the group consisting of cyclohexylcyclopentyldimethoxysilane, cyclohexyleyelopen y1- diethoxysilane, 3-methylcyclohexylcyclopentyldimethoxysilane, 4-methylcyclohexylcyclopentyldimethoxysilane and 3,5-dimethyl- cyc1ohexy1eye1opentyldimethoxysi1ane.
11. A process for polymerizing an olefin comprising homo- or copolymerizing an olefin in the presence of a catalyst for the polymerization of olefins comprising (A) a solid catalyst component essentially containing magnesium, titanium, an electron donor compound, and a halogen which is prepared by bringing a magnesium compound, a titanium halide compound, and an electron donor compound into contact, (B) an organoaluminum compound, and (C) an organosilicon compound represented by formula (I):
wherein R1 and R2, which may be the same or different, each represents an alkyl group having from 1 to 3 carbon atoms; R3 and R4, which may be the same or different, each represents an alkyl group having from 1 to 3 carbon atoms, or a halogen atom; and and n each represents 0 or an integer of 1 or 2.
12. The process as claimed in claim 11, wherein said olefin is propylene or a combination of propylene and ethylene.
PCT/JP1995/000847 1994-04-28 1995-04-27 Organosilicon compound, ziegler-natta catalyst containing the same and process for polymerization of olefins WO1995029939A1 (en)

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CN112574341A (en) * 2020-12-17 2021-03-30 沧州利和科技发展有限责任公司 Catalyst component for synthesizing high-rigidity polypropylene, catalyst and preparation method thereof

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JPH0284404A (en) * 1988-06-17 1990-03-26 Mitsui Petrochem Ind Ltd Polymerization of olefin and catalyst therefor
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KR100430978B1 (en) * 2000-12-29 2004-05-12 삼성아토피나주식회사 Method for producing supported catalyst for producing ethylene polymer and ethylene/alpha-olefin copolymer
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