Classifications

• • 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
  • C07F5/00—Compounds containing elements of Groups 3 or 13 of the Periodic Table
  • C07F5/02—Boron compounds
  • C07F5/027—Organoboranes and organoborohydrides

Definitions

• the present invention relates to salts and catalyst systems for the polymerization of olef ⁇ ns comprising such salts.
• the invention also relates to a process for the polymerization of olefins carried out in the presence of the above catalyst systems.
• Homogeneous catalytic systems based on metallocene complexes are known to be active the polymerization of olef ⁇ ns; said complexes must be activated by means of suitable cocatalytic compounds.
• the first generation of cocatalysts developed for homogeneous metallocene olefin polymerization consisted of alkyl aluminum chlorides (A1R 2 C1), wherein substituents R are preferably methyl or ethyl; these cocatalysts exhibit low ethylene polymerization activity levels and negligible propylene polymerization activity.
• the second generation of cocatalyst systems comprised the class of alkylalunioxanes, commonly obtained by reacting trialkyl aluminum compound and water in a molar ratio of 1 : 1 to 100:1; these alumoxanes are oligomeric linear and/or cyclic compounds represented by the formulae:
• n ranges from 0 to 40
• m ranges from 3 to 40.
• Methylalumoxane (MAO) is the most widely used cocatalyst. Nevertheless alkylalunioxanes, and in particular methylalumoxane, though very active in metallocene-based catalyst systems, exhibit several inherent problems in use, such as the need for high alumoxane/metallocene molar ratios to produce satisfactory catalytic activities, their high reactivity toward impurities (moisture, alcohols etc.) and their easy flammability.
• B(C 6 F 5 ) 4 types of non-coordinating anions have been developed as cocatalysts for metallocene-based systems. More specifically, these activators are ion-exchange compounds comprising a trialkyl or dialkylammonium cation, which will irreversibly react with a metallocene, and a fluorinated arylborate anion, capable of stabilizing the metallocene cation complex and sufficiently labile to permit displacement by the monomer during polymerization (see for instance WO 91/02012).
• activators are tri(n- butyl)ammom ' um tetrakis(pentafluorophenyl)boron and N,N-dimethylanilinium tetrakis(pentafluorophenyl)boron.
• WO 99/42467 discloses a catalyst activator of general formula (A 1+a ) b (Z 1 J ⁇ ) " ⁇ wherein A 1 is a cation of charge +a; Z 1 is an anion group of from 1 to 50, preferably 1 to 30 atoms, not counting hydrogen atoms, further containing two or more Lewis base sites; J 1 independently each occurrence is a Lewis acid coordinated to at least one Lewis base site of Z 1 , and optionally two or more such J 1 groups may be joined together in a moiety having multiple Lewis acidic functionality; j is a number from 2 to 12 and a, b, c and d are integers from 1 to 3, with the proviso that a x b is equal to c x d.
• One of preferred group Z is imidazole and its derivatives.
• the drawback of these catalyst activators is that one equivalent of activator contains two equivalents of the Lewis acid that usually is the most expensive part of the activator.
• the Applicant has now found a new class of olefin polymerization cocatalysts, which reduces the use of excess of cocatalyst with respect to alkylaluminoxanes .
• the present invention concerns a salt of formula (I):
• K is a nitrogen (N) or phosphorous (P) atom; preferably K is nitrogen;
• R 1 equal to or different from each other, is selected from the group consisting of linear or branched, saturated or unsaturated, C1-C30 alkyl, C 6 -C 0 aryl, C -C 20 arylalkyl and C 7 -C 20 alkylaryl groups, optionally containing O, S, N, P, Si or halogen atoms, or two R 1 can form one C 4 -C 7 ring, optionally containing O, S, N, P or Si atoms, that can bear substituents; preferably R 1 a linear or branched, saturated or unsaturated, Ci-C 3 Q alkyl radical; T 1 is a Lewis acid, that form a complex with T , T having formula (II)
• MtR 2 3 (II) wherein Mt is a metal belonging to Group 13 of the Periodic Table of the Elements (IUPAC); R , equal to or different from each other, are selected from the group consisting of halogen, halogenated C 6 -C 20 aryl and halogenated C 7 -C 20 alkylaryl groups; two R 2 groups can also form with the metal Mt one condensed ring, such as for example 9-borafluorene compounds.
• IUPAC Periodic Table of the Elements
• Mt is B or Al, and more preferably is B;
• the substituents R 2 are preferably selected from the group consisting of C 6 F 5 , C 6 F H, C 6 F 3 H , C 6 H 3 (CF 3 ) 2 , perfluoro-biphenyl, heptafluoro-naphthyl, hexafluoro-naphthyl and pentafluoro-naphthyl; most preferred R 2 substituents are C 6 F 5 radicals; T 2 is a moiety of formula (III) bonding T 1 through the nitrogen atom
• R 3 , R 4 , R 5 and R 6 equal to or different from each other are selected from the group consisting of hydrogen, halogen, linear or branched, saturated or unsaturated, C Cio alkyl, C 6 - C 20 aryl, C -C 2 o arylalkyl and C -C 2 o alkylaryl groups, optionally containing O, S, N, P, Si or halogen atoms, or two or more adjacent substituents R 4 , R 5 , R 6 and R 7 form one or more C 4 -C rings, optionally containing O, S, N, P or Si atoms, that can bear substituents; with the proviso that at least one R 3 , R 4 , R 5 and R 6 is different from hydrogen.
• Preferred moiety of formula (III) are those belonging to formula (IV).
• substituents R 3 and R 4 have the meaning reported above and the substituents R 7 , equal to or different from each other, are selected from the group consisting of hydrogen, halogen, linear or branched, saturated or unsaturated, - o alkyl, C 6 -C 20 aryl, C -C 20 arylalkyl and C -
• R 3 and R 4 are hydrogen.
• anion [T ! T 2 ] " are:
• Non limitative examples of moiety Fff - are: trimethylammonium; triethylammonium; tripropylammom ' um; tri(n-butyl)ammonium; methyldi(octadecyl)ammonium; N,-methylanilinium; N-ethylanilinium; N-methyl(2, 4, 6- trimethyl)anilinium; and methyldicyclohexylammonium.
• the salt object of the present invention can easily be prepared by contacting in any order i) about one equivalent of a compound of formula (V)
• a preferred process comprises the following steps: a) contacting about one equivalent of a compound of formula (V)
• step a) optionally isolating the reaction product of step a) and then adding about one equivalent of a compound of formula KR ! 3 wherein K and R 1 have been described above.
• the two steps described above can be carried out both by isolating the intermediate product formed in step a), generally by filtration or evaporation of the solvent, or carried out "one pot" without isolating the intermediate product, preferably the reaction is carried out in an aprotic solvent, even more preferably in a polar aprotic solvent (such as toluene, diethyl ether or CH 2 C1 2 ), at room temperature.
• the reaction can be carried out also in the presence of little amount of water, preferably equal to or less than one molar equivalent with respect to the Lewis acid.
• the final product is generally isolated by filtration or evaporation of the solvent. It is another object of the present invention a catalyst system for the polymerization of olef ⁇ ns comprising the product obtainable by contacting:
• Transition metal organometallic compounds for use in the catalyst system in accordance with the present invention are compounds suitable as olefin polymerization catalysts by coordination or insertion polymerization.
• the class includes known transition organometallic compounds useful in Ziegler-Natta coordination polymerization, such as the group IN metallocene compounds and the late transition metal. These will tipically include Group 4-10 transition metal compounds wherein at least one metal ligand can be abstracted by the catalyst activators.
• the transition metal organometallic catalyst compounds can be used as such, otherwise an alkylating agent has to be used in order to alkylate said catalyst.
• the alkylation can be carried out in a separate step or in situ.
• the alkylating agent is a compound able to react with the transition metal organometallic catalyst compounds and exchange said ligand that can be abstracted, with an alkyl group.
• said alkylating agent is selected from the group consisting of R ⁇ Li, R ⁇ ⁇ a, R ⁇ K, R ⁇ MgU or A1R 11 3 - Z W Z , or alumoxanes, wherein R 11 can be Ci- o alkyl, alkenyl or alkylaryl radicals, optionally containing one or more Si or Ge atoms, z is 0, 1 or 2 or a non integer number ranging from 0 to 2; U is chlorine, bromine or iodine and W is hydrogen or chlorine, bromine or iodine atom; non-limiting examples of R 11 are methyl, ethyl, butyl and benzyl; non limiting example of A1R 11 3-Z W Z compounds are trimethylaluminum (TMA), tris(2,4,4-
• Non limiting example of alumoxanes are: methylalumoxane (MAO), tetra-(isobutyl)alumoxane (TIBAO), tetra-(2,4,4-trimethyl-pentyl)alumoxane (TIOAO), tetra-(2,3- dimethylbutyl)alun ⁇ oxane (TDMBAO) and tetra-(2,3,3-trimethylbutyl)alumoxane (TTMBAO).
• MAO methylalumoxane
• TIBAO tetra-(isobutyl)alumoxane
• TIOAO tetra-(2,4,4-trimethyl-pentyl)alumoxane
• TDMBAO tetra-(2,3- dimethylbutyl)alun ⁇ oxane
• TTMBAO tetra-(2,3,3-trimethylbutyl)alumoxane
• a preferred class of transition metal organometallic compounds are metallocene compounds belonging to the following formula (VIII)
• A is O, S, NR 9 , PR 9 wherein R 9 is hydrogen, a linear or branched, saturated or unsaturated C 1 -C 20 alkyl, C 3 -C 2 o cycloalkyl, C 6 -C 20 aryl, C 7 -C 20 alkylaryl or C -C 20 arylalkyl, or A has the same meaning of Cp; M is a transition metal belonging to group 4, 5 or to the lanthanide or actinide groups of the Periodic Table of the Elements (IUPAC version); the substituents L, equal to or different from each other, are monoanionic sigma ligands selected from the group consisting of hydrogen, halogen, R 10 , OR 10 , OCOR 10 , SR 10 , NR 10 2 and PR 10 2 , wherein R 10 is a linear or branched, saturated or unsaturated C1-C 20 alkyl, C -C 20 cycloalkyl, C 6 -C 0 aryl
• the divalent bridge (ZR 8 m ) n is preferably selected from the group consisting of CR 8 2 , (CR 8 2 ) 2 , (CR 8 2 ) 3 , SiR 8 2 , GeR 8 2 , NR 8 and PR 8 , R 8 having the meaning reported above; more preferably, said divalent bridge is Si(CH 3 ) 2 , SiPh 2 , CH 2 , (CH 2 ) 2 , (CH 2 ) 3 or C(CH 3 ) 2 .
• variable m is preferably 1 or 2; the variable n ranges preferably from 0 to 4 and, when n > 1, the atoms Z can be the same or different from each other, such as in divalent bridges CH 2 - O, CH 2 -S and CH 2 -Si(CH 3 ) 2 .
• the ligand Cp which is 7r-bonded to said metal M, is preferably selected from the group consisting of cyclopentadienyl, mono-, di- 3 tri- and tetra-methyl cyclopentadienyl; 4- yl- cyclopentadienyl; 4-adamantyl-cyclopentadienyl; indenyl; mono-, di-, tri- and tetra-methyl indenyl; 2-methyl indenyl, S- ⁇ jutyl-indenyl, 4-phenyl indenyl, 4,5 benzo indenyl; 3- trimethylsilyl-indenyl; 4,5,6,7-tetrahydroindenyl; fluorenyl; 5,10-dihydroindeno[l,2-b]indol- 10-yl; N-methyl- or N-phenyl-5,10-dihydroindeno [l,2-b]indol-10-yl; 5,6-
• the group A is O, S, N(R 9 ), wherein R 9 is hydrogen, a linear or branched, saturated or unsaturated C ⁇ -C 20 alkyl, C 3 -C 20 cycloalkyl, C 6 -C 20 aryl, C -C 20 alkylaryl or C -C 2 o arylalkyl, preferably R 9 is methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl, phenyl, p-n-butyl-phenyl, benzyl, cyclohexyl and cyclododecyl; more preferably R 9 is t-butyl; or A has the same meaning of Cp.
• Non limiting examples of compounds belonging to formula (VET) are the rac and meso form (when present) of the following compounds: bis(cyclopentadienyl)zirconium dimethyl; bis(indenyl)zirconium dimethyl; bis(tetrahydroindenyl)zirconium dimethyl; bis(fluorenyl)zirconium dimethyl; (cyclopentadienyi ⁇ indenyl)zirconium dimethyl; (cyclopentadienyl)(fluorenyl)zirconium dimethyl; (cyclopentadienyl)(tetrahydroindenyl)zirconium dimethyl; (fluorenyl)(indenyl)zirconium dimethyl; dimethylsilanediylbis(indenyl)zirconium dimethyl, dimethylsilanediylbis(2-methyl-4-phenylindenyl)zirconium dimethyl, dimethylsilanediylbis(
• a suitable class of metallocene complexes (A) for use in the catalysts complexes of the invention comprises the well-known constrained geometry catalysts, as described in EP-A-0416 815, EP-A-0420436, EP-A-0 671 404, EP-A-0 643 066 and WO-A-91/04257.
• the group A has the same meaning of Cp, and is preferably substituted or unsubstituted cyclopentadienyl, indenyl, tetrahydroindenyl (2,5-dimethyl-cyclopenta[l,2- b:4,3-b']-dithiophene).
• Suitable metallocene complexes that may be used in the catalyst system according to the present invention are described in WO 98/22486, WO 99/58539 WO 99/24446, USP 5,556,928, WO 96/22995, EP-485822, EP-485820, USP 5,324,800 and EP- A-0 129 368.
• the metal M is preferably Ti, Zr or Hf, and more preferably Zr.
• the substituents L are preferably the same and are selected from the group consisting of halogens, R 10 , OR 10 and NR 10 2 ; wherein R 10 is a C C 7 alkyl, C 6 -C 14 aryl or C 7 -C 14 arylalkyl group, optionally containing one or more Si or Ge atoms; more preferably, the substituents L are selected from the group consisting of -Cl, -Br, -Me, -Et, -n-Bu, -sec-Bu, -Ph, -Bz, - CH SiMe 3 , -OEt, -OPr, -OBu, -OBz and -NMe 2 , even more preferably L is methyl.
• the integer n ranges from 0 to 4, and it is preferably 1 or 2.
• A can have only the meaning of Cp;
• Cp and A are preferably pentamethyl cyclopentadienyl, indenyl or 4,5,6,7-tetrahydroindenyl groups.
• Cp and A are preferably cyclopentadienyl, tetramethyl-cyclopentadienyl, indenyl, 4,5,6,7-tetra-hydro-indenyl, 2- methyl-4,5,6,7-tetra-hydro-indenyl, 4,7-dimethyl-4,5,6,7-tetra-hydroindenyl, 2,4,7-trimethyl- 4,5,6,7-tetra-hydro-indenyl or fluorenyl groups; (ZR 8 m ) n is preferably Me Si, Me 2 C, CH 2 or C2H4.
• Suitable metallocene complexes (A) are the bridged bis-indenyl metallocenes as described for instance in USP 5,145,819 and EP-A-0 485 823.
• metallocene complexes suitable for the catalyst system of the invention are the classes of heterocyclic metallocenes described in WO 98/22486 and WO 99/24446. Among these metallocenes, particularly preferred are the ones reported from page 15, line 8 to page 24, line 17; from page 25, line 1 to page 31, line 9; and from page 58, penultimate line, to page 63, line 20 of WO 98/22486. Other preferred metallocenes are the ones obtained from the bridged ligands listed from page 11, line 18, to page 14, line 13 of WO 99/24446 A further preferred class of transition metal organometallic catalyst compounds are late transition metal complex of formula (LX) or (X)
• B is a -Cso bridging group linking E 1 and E 2 , optionally containing one or more atoms belonging to Groups 13-17 of the Periodic Table;
• E 1 and E 2 are elements belonging to Group 15 or 16 of the Periodic Table and are bonded to said metal M a ;
• the substituents R l equal to or different from each other, are selected from the group consisting of hydrogen, linear or branched, saturated or unsaturated -C 20 alkyl, C 3 -C 2 o cycloalkyl, C 6 -C2 0 aryl, C -C2 0 alkylaryl and C -C 2 o arylalkyl radicals, optionally containing one or more atoms belonging to groups 13-17 of the Periodic Table of the Elements (such as B, Al, Si, Ge, N, P, O, S, F and Cl atoms); or two R al substituents attached to the same atom E 1 or E 2 form a saturated, unsaturated or aromatic C 4 -C 7 ring, having from 4 to 20 carbon atoms; m a and n a are independently 0, 1 or 2, depending on
• Non limiting examples of late transition metal complexes are those described in WO 96/23010, WO 97/02298, WO 98/40374 and J.Am. Chem. Soc. 120:4049-4050, 1998. Brookhart et al, J. Am. Chem. Soc. 1995, 117, 6414 and Brookhart et al, J. Am. Chem. Soc, 1996, 118, 267, Brookhart et al, J. Am. Chem. Soc. 1998, 120, 4049, Gibson et al, Chem. Commun. 1998, 849, WO 96/27439 and Chem. Ber./Recl. (1997), 130(3), 399-403. It is a further object of the present invention a process for the polymerization of one or more olefins in the presence of a catalyst system as described above.
• the salts according to the invention exert good activities as cocatalysts in olefin polymerization process; moreover, they are easy to prepare. Further they are stable and produce stable catalyst compositions under polymerization conditions.
• the molar ratio between the salt (B) and the transition metal organometallic compound (A), calculated as the molar ratio between the Lewis acid and the metal of the transition metal organometallic catalyst compound preferably ranges from 10:1 to 1:10, more preferably from 2:1 to 1:2, and even more preferably is about 1:1.
• component (B) can suitably comprise a mixture of two or more salt of the invention.
• component (B) can be used in combination with other compatible cocatalysts known in the state of the art, such as alumoxane compounds.
• the catalyst system of the invention may also comprise one or more aluminum compounds of formula AlR ⁇ - z W Z) acting as scavenger, wherein R 11 can be Ci- o alkyl, alkenyl or alkylaryl radicals, optionally containing one or more Si or Ge atoms, z is 0, 1 or 2 or a non integer number ranging from 0 to 2; U is chlorine, bromine or iodine atom and W is hydrogen, chlorine, bromine or iodine; non-limiting examples of aluminum compounds are trimethylaluminum (TMA), tris(2,4,4-trimethyl-pentyl)aluminum (TIOA), tris(2-methyl-propyl)aluminum (TUBA), tris(2,3,3-trimethyl-butyl)aluminum, 1ris(2,3-dime1
• n 1 is 0 or an integer from 1 to 40 and the R substituents are defined as above, or alumoxanes of the formula:
• (A I l— 0)n 2 2 can be used in the case of cyclic compounds, wherein n is an integer from 2 to 40 and the
• R 12 substituents are defined as above.
• alumoxanes suitable as scavenger according to the present invention are methylalumoxane (MAO), tetra-(isobutyl)alumoxane
• TIOAO tetra-(2,4,4-trimethyl-pentyl)alumoxane
• TIOAO tetra-(2,4,4-trimethyl-pentyl)alumoxane
• TDMBAO tetra-(2,3- dimethylbutyl) alumoxane
• the catalyst system of the invention may be formed prior to its introduction into a polymerization reactor or in situ in the reactor, by contacting the above-described components
• components (B) and optionally (C) are first contacted and then introduced into the reactor, otherwise the component (C) can be separately introduced in the reactor.
• components (A), (B) and optionally (C) may be contacted together in the reactor.
• the catalysts of the present invention can be used on inert supports.
• inert supports such as silica, alumina, styrene/divinylbenzene copolymers, polyethylene or polypropylene.
• the thus obtained solid compound can be suitably used in gas phase polymerization.
• the catalysts of the present invention can be used in the polymerization reactions of olef ⁇ ns.
• the invention provides a process for the polymerization of one or more olefins comprising contacting one or more olef ⁇ ns under polymerization conditions in the presence of a catalyst system as described above.
• the catalysts according to the present invention can be conveniently used in the homopolymerization of ethylene, in particular for the preparation of HDPE, and in the copolymerization of ethylene, in particular for the preparation of LLDPE, plastomers or elastomers.
• olef ⁇ ns examples include propylene, 1-butene, 1-pentene, 4-methyl- 1-pentene, 1-hexene, 1-octene, allyl-cyclohexane, cyclopentene, cyclohexene, norbornene and 4,6-dimethyl-l- heptene.
• Further suitable comonomers in said ethylene copolymers are polyenes, in particular conjugated or non-conjugated, linear or cyclic dienes, such as 1,4-hexadiene, isoprene, 1,3- butadiene, 1,5-hexadiene and 1,6-heptadiene.
• organometallic compounds object of the present invention When used as cocatalyst in copolymerization of ethylene they generally produce a polymer having a higher molecular weight with respect to alumoxanes, in particular methylalumoxane.
• the catalysts of the invention can be suitably used in propylene polymerization, for example for the production of isotactic or elastomeric polypropylene.
• the catalysts according to the present invention are used in the preparation of cycloolefin polymers.
• Monocyclic and polycyclic olefin monomers can be either homopolymerized or copolymerized, also with linear olefin monomers.
• the polymerization processes of the present invention can be carried out in liquid phase, optionally in the presence of an inert hydrocarbon solvent, or in gas phase.
• Said hydrocarbon solvent can be either aromatic (such as toluene) or aliphatic (such as propane, hexane, heptane, isobutane, cyclohexane and 2,2,4-trimethylpentane).
• the polymerization temperature preferably ranges from 0°C to 250°C; in the preparation of HDPE and LLDPE, it is preferably comprised between 20°C and 150°C and, more particularly between 40°C and 90°C; in the preparation of elastomeric copolymers, it is preferably comprised between 0°C and 200°C, and more preferably between 20°C and 100°C.
• the molecular weight of the polymers can be varied simply by varying the polymerization temperature, the type or the concentration of the catalyst components, or by using molecular weight regulators, such as hydrogen.
• the molecular weight distribution can be varied by using mixtures of different metallocene complexes or by carrying out the polymerization in several stages which differ in the polymerization temperature and/or the concentrations of molecular weight regulator.
• the polymerization yield depends on the purity of the transition metal organometallic catalyst compound (A) in the catalyst, therefore, said compound can be used as such or can be subjected to purification treatments before use.
• the following examples are given for illustrative and not limiting purposes.
• Triethylamine (Aldrich, or Fluka, purity
• CD 2 C1 2 (Aldrich, 99.8% atom D) was used as received, while C 6 D 6 (Aldrich, 99% atom D) were dried over activated 4 A° molecular sieves before use. Preparation of the samples was carried out under nitrogen by using standard inert atmosphere techniques.
• the melting points of the compounds were obtained by using a capillary Electrothermal instrument.
• the intrinsic viscosity (IN.) was measured in TH ⁇ at 135°C.
• TIB A in hexane (amounts specified in Table 1) as a scavenger.
• Propylene and ethylene were then pressurized into the reactor, to reach the composition of 1.2 wt% ethylene and
• the catalyst system was prepared by dissolving 5 mg of ind 2 ZrMe in 5 mL toluene, and then quickly adding the cocatalyst indicated in table 1 in 5 mL toluene (Zr/cocat molar ration 1:1).
• the polymerization was started by injecting the toluene solution containing catalyst system into the autoclave at the polymerization temperature, by means of ethylene overpressure, then the temperature was maintained at the polymerization temperature, and ethylene was continuously fed into the reactor in order to maintain a constant pressure.
• the ethylene/propylene amorphous copolymer was recovered from the hexane solution by precipitation in acetone, followed by drying under reduced atmosphere at 70 °C for 4 hours.

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