WO2014132759A1 - プロピレン系ブロック共重合体の製造方法 - Google Patents
プロピレン系ブロック共重合体の製造方法 Download PDFInfo
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- WO2014132759A1 WO2014132759A1 PCT/JP2014/052624 JP2014052624W WO2014132759A1 WO 2014132759 A1 WO2014132759 A1 WO 2014132759A1 JP 2014052624 W JP2014052624 W JP 2014052624W WO 2014132759 A1 WO2014132759 A1 WO 2014132759A1
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- WIPO (PCT)
- Prior art keywords
- group
- carbon atoms
- halogen
- propylene
- substituted
- Prior art date
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- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 title claims abstract description 105
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 title claims abstract description 105
- 229920001400 block copolymer Polymers 0.000 title claims abstract description 69
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 46
- 239000011949 solid catalyst Substances 0.000 claims abstract description 139
- 238000006116 polymerization reaction Methods 0.000 claims abstract description 90
- 150000001875 compounds Chemical class 0.000 claims abstract description 73
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 70
- 239000010936 titanium Substances 0.000 claims abstract description 67
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims abstract description 34
- 239000004711 α-olefin Substances 0.000 claims abstract description 26
- 239000003054 catalyst Substances 0.000 claims abstract description 25
- 229910052736 halogen Inorganic materials 0.000 claims abstract description 24
- 150000002367 halogens Chemical class 0.000 claims abstract description 24
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 18
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 18
- 239000011777 magnesium Substances 0.000 claims abstract description 16
- -1 vinyloxy group Chemical group 0.000 claims description 307
- 125000004432 carbon atom Chemical group C* 0.000 claims description 239
- 150000002430 hydrocarbons Chemical group 0.000 claims description 79
- 238000000034 method Methods 0.000 claims description 62
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 43
- 239000005977 Ethylene Substances 0.000 claims description 43
- 125000002029 aromatic hydrocarbon group Chemical group 0.000 claims description 40
- 125000000217 alkyl group Chemical group 0.000 claims description 37
- 125000003342 alkenyl group Chemical group 0.000 claims description 36
- 238000007334 copolymerization reaction Methods 0.000 claims description 33
- 150000003961 organosilicon compounds Chemical class 0.000 claims description 30
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 27
- 229910052799 carbon Inorganic materials 0.000 claims description 25
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 24
- 125000000753 cycloalkyl group Chemical group 0.000 claims description 23
- 125000000392 cycloalkenyl group Chemical group 0.000 claims description 21
- 125000004430 oxygen atom Chemical group O* 0.000 claims description 18
- JWCYDYZLEAQGJJ-UHFFFAOYSA-N dicyclopentyl(dimethoxy)silane Chemical compound C1CCCC1[Si](OC)(OC)C1CCCC1 JWCYDYZLEAQGJJ-UHFFFAOYSA-N 0.000 claims description 17
- 229910052757 nitrogen Inorganic materials 0.000 claims description 15
- 125000005843 halogen group Chemical group 0.000 claims description 13
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 12
- 229910052698 phosphorus Inorganic materials 0.000 claims description 12
- 239000011574 phosphorus Substances 0.000 claims description 12
- 239000010703 silicon Substances 0.000 claims description 11
- 229910052710 silicon Inorganic materials 0.000 claims description 11
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 10
- 150000001721 carbon Chemical group 0.000 claims description 10
- 125000004435 hydrogen atom Chemical group [H]* 0.000 claims description 10
- 125000004433 nitrogen atom Chemical group N* 0.000 claims description 10
- 125000001424 substituent group Chemical group 0.000 claims description 10
- 125000003282 alkyl amino group Chemical group 0.000 claims description 9
- 229910000077 silane Inorganic materials 0.000 claims description 9
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims description 7
- 125000004429 atom Chemical group 0.000 claims description 7
- VHPUZTHRFWIGAW-UHFFFAOYSA-N dimethoxy-di(propan-2-yl)silane Chemical compound CO[Si](OC)(C(C)C)C(C)C VHPUZTHRFWIGAW-UHFFFAOYSA-N 0.000 claims description 7
- KOFGHHIZTRGVAF-UHFFFAOYSA-N n-ethyl-n-triethoxysilylethanamine Chemical compound CCO[Si](OCC)(OCC)N(CC)CC KOFGHHIZTRGVAF-UHFFFAOYSA-N 0.000 claims description 7
- 125000003545 alkoxy group Chemical group 0.000 claims description 6
- 125000003118 aryl group Chemical group 0.000 claims description 5
- YQGOWXYZDLJBFL-UHFFFAOYSA-N dimethoxysilane Chemical compound CO[SiH2]OC YQGOWXYZDLJBFL-UHFFFAOYSA-N 0.000 claims description 5
- 125000005017 substituted alkenyl group Chemical group 0.000 claims description 5
- BHPDSAAGSUWVMP-UHFFFAOYSA-N 3,3-bis(methoxymethyl)-2,6-dimethylheptane Chemical compound COCC(C(C)C)(COC)CCC(C)C BHPDSAAGSUWVMP-UHFFFAOYSA-N 0.000 claims description 4
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical compound CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 claims description 4
- RGHIYOCUMCUWAQ-UHFFFAOYSA-N 3,3-bis(methoxymethyl)-2,5-dimethylhexane Chemical compound COCC(COC)(CC(C)C)C(C)C RGHIYOCUMCUWAQ-UHFFFAOYSA-N 0.000 claims description 3
- ZWINORFLMHROGF-UHFFFAOYSA-N 9,9-bis(methoxymethyl)fluorene Chemical compound C1=CC=C2C(COC)(COC)C3=CC=CC=C3C2=C1 ZWINORFLMHROGF-UHFFFAOYSA-N 0.000 claims description 3
- 125000002915 carbonyl group Chemical group [*:2]C([*:1])=O 0.000 claims description 3
- SJJCABYOVIHNPZ-UHFFFAOYSA-N cyclohexyl-dimethoxy-methylsilane Chemical compound CO[Si](C)(OC)C1CCCCC1 SJJCABYOVIHNPZ-UHFFFAOYSA-N 0.000 claims description 3
- IKUDHFZOVQKVAX-UHFFFAOYSA-N dimethoxy-bis(3-methylbutyl)silane Chemical compound CC(C)CC[Si](OC)(CCC(C)C)OC IKUDHFZOVQKVAX-UHFFFAOYSA-N 0.000 claims description 3
- RXVAWVPVNXHVFX-UHFFFAOYSA-N n-[dicyclopentyl(ethylamino)silyl]ethanamine Chemical compound C1CCCC1[Si](NCC)(NCC)C1CCCC1 RXVAWVPVNXHVFX-UHFFFAOYSA-N 0.000 claims description 3
- NETBVGNWMHLXRP-UHFFFAOYSA-N tert-butyl-dimethoxy-methylsilane Chemical compound CO[Si](C)(OC)C(C)(C)C NETBVGNWMHLXRP-UHFFFAOYSA-N 0.000 claims description 3
- PSWKAZOCOHMXCW-UHFFFAOYSA-N tert-butyl-ethyl-dimethoxysilane Chemical compound CC[Si](OC)(OC)C(C)(C)C PSWKAZOCOHMXCW-UHFFFAOYSA-N 0.000 claims description 3
- ZNOCGWVLWPVKAO-UHFFFAOYSA-N trimethoxy(phenyl)silane Chemical compound CO[Si](OC)(OC)C1=CC=CC=C1 ZNOCGWVLWPVKAO-UHFFFAOYSA-N 0.000 claims description 3
- 125000003302 alkenyloxy group Chemical group 0.000 claims description 2
- 125000004104 aryloxy group Chemical group 0.000 claims description 2
- 125000000000 cycloalkoxy group Chemical group 0.000 claims description 2
- FSCIRKQLFHLTOX-UHFFFAOYSA-N cyclohexyl-cyclopentyl-dimethoxysilane Chemical compound C1CCCCC1[Si](OC)(OC)C1CCCC1 FSCIRKQLFHLTOX-UHFFFAOYSA-N 0.000 claims description 2
- MGGAITMRMJXXMT-UHFFFAOYSA-N cyclopentyl(triethoxy)silane Chemical compound CCO[Si](OCC)(OCC)C1CCCC1 MGGAITMRMJXXMT-UHFFFAOYSA-N 0.000 claims description 2
- 125000004663 dialkyl amino group Chemical group 0.000 claims description 2
- AHUXYBVKTIBBJW-UHFFFAOYSA-N dimethoxy(diphenyl)silane Chemical compound C=1C=CC=CC=1[Si](OC)(OC)C1=CC=CC=C1 AHUXYBVKTIBBJW-UHFFFAOYSA-N 0.000 claims description 2
- 125000001183 hydrocarbyl group Chemical group 0.000 claims description 2
- WMZBXHDZOQZUGO-UHFFFAOYSA-N n-[dicyclohexyl(ethylamino)silyl]ethanamine Chemical compound C1CCCCC1[Si](NCC)(NCC)C1CCCCC1 WMZBXHDZOQZUGO-UHFFFAOYSA-N 0.000 claims description 2
- LFQCEHFDDXELDD-UHFFFAOYSA-N tetramethyl orthosilicate Chemical compound CO[Si](OC)(OC)OC LFQCEHFDDXELDD-UHFFFAOYSA-N 0.000 claims description 2
- JCVQKRGIASEUKR-UHFFFAOYSA-N triethoxy(phenyl)silane Chemical compound CCO[Si](OCC)(OCC)C1=CC=CC=C1 JCVQKRGIASEUKR-UHFFFAOYSA-N 0.000 claims description 2
- XGZGKDQVCBHSGI-UHFFFAOYSA-N butyl(triethoxy)silane Chemical compound CCCC[Si](OCC)(OCC)OCC XGZGKDQVCBHSGI-UHFFFAOYSA-N 0.000 claims 1
- SXPLZNMUBFBFIA-UHFFFAOYSA-N butyl(trimethoxy)silane Chemical compound CCCC[Si](OC)(OC)OC SXPLZNMUBFBFIA-UHFFFAOYSA-N 0.000 claims 1
- ATGKAFZFOALBOF-UHFFFAOYSA-N cyclohexyl(triethoxy)silane Chemical compound CCO[Si](OCC)(OCC)C1CCCCC1 ATGKAFZFOALBOF-UHFFFAOYSA-N 0.000 claims 1
- MEWFSXFFGFDHGV-UHFFFAOYSA-N cyclohexyl(trimethoxy)silane Chemical compound CO[Si](OC)(OC)C1CCCCC1 MEWFSXFFGFDHGV-UHFFFAOYSA-N 0.000 claims 1
- YRMPTIHEUZLTDO-UHFFFAOYSA-N cyclopentyl(trimethoxy)silane Chemical compound CO[Si](OC)(OC)C1CCCC1 YRMPTIHEUZLTDO-UHFFFAOYSA-N 0.000 claims 1
- NHYFIJRXGOQNFS-UHFFFAOYSA-N dimethoxy-bis(2-methylpropyl)silane Chemical compound CC(C)C[Si](OC)(CC(C)C)OC NHYFIJRXGOQNFS-UHFFFAOYSA-N 0.000 claims 1
- FDYPWIDITZJTAI-UHFFFAOYSA-N n-ethyl-n-trimethoxysilylethanamine Chemical compound CCN(CC)[Si](OC)(OC)OC FDYPWIDITZJTAI-UHFFFAOYSA-N 0.000 claims 1
- 150000001336 alkenes Chemical class 0.000 abstract description 33
- 239000001257 hydrogen Substances 0.000 abstract description 20
- 229910052739 hydrogen Inorganic materials 0.000 abstract description 20
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 abstract description 19
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 abstract description 19
- 230000000694 effects Effects 0.000 abstract description 15
- 230000037048 polymerization activity Effects 0.000 abstract description 12
- 239000002904 solvent Substances 0.000 description 48
- IMNFDUFMRHMDMM-UHFFFAOYSA-N N-Heptane Chemical compound CCCCCCC IMNFDUFMRHMDMM-UHFFFAOYSA-N 0.000 description 45
- 239000002685 polymerization catalyst Substances 0.000 description 42
- 238000006243 chemical reaction Methods 0.000 description 37
- 239000002245 particle Substances 0.000 description 37
- 229920000642 polymer Polymers 0.000 description 37
- 229930195733 hydrocarbon Natural products 0.000 description 34
- 239000004215 Carbon black (E152) Substances 0.000 description 33
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 30
- 230000015572 biosynthetic process Effects 0.000 description 28
- 239000012265 solid product Substances 0.000 description 25
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- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 16
- 229920000181 Ethylene propylene rubber Polymers 0.000 description 16
- 239000007795 chemical reaction product Substances 0.000 description 16
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- 238000005259 measurement Methods 0.000 description 15
- 125000004450 alkenylene group Chemical group 0.000 description 14
- 150000002681 magnesium compounds Chemical class 0.000 description 14
- 229920001296 polysiloxane Polymers 0.000 description 14
- 238000002360 preparation method Methods 0.000 description 14
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 13
- 239000004743 Polypropylene Substances 0.000 description 13
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 12
- 239000000047 product Substances 0.000 description 12
- XJDNKRIXUMDJCW-UHFFFAOYSA-J titanium tetrachloride Chemical compound Cl[Ti](Cl)(Cl)Cl XJDNKRIXUMDJCW-UHFFFAOYSA-J 0.000 description 12
- 238000005160 1H NMR spectroscopy Methods 0.000 description 10
- 238000009826 distribution Methods 0.000 description 9
- HQQADJVZYDDRJT-UHFFFAOYSA-N ethene;prop-1-ene Chemical group C=C.CC=C HQQADJVZYDDRJT-UHFFFAOYSA-N 0.000 description 9
- 229920001155 polypropylene Polymers 0.000 description 9
- 239000000843 powder Substances 0.000 description 9
- 238000003786 synthesis reaction Methods 0.000 description 9
- 238000012360 testing method Methods 0.000 description 9
- 150000003609 titanium compounds Chemical class 0.000 description 9
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 8
- YIWUKEYIRIRTPP-UHFFFAOYSA-N 2-ethylhexan-1-ol Chemical compound CCCCC(CC)CO YIWUKEYIRIRTPP-UHFFFAOYSA-N 0.000 description 8
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- SNLNBKLOVKUQHS-UHFFFAOYSA-N (1,4-dimethylcyclohexa-2,4-dien-1-yl) hydrogen carbonate Chemical compound CC1=CCC(C=C1)(C)OC(=O)O SNLNBKLOVKUQHS-UHFFFAOYSA-N 0.000 description 7
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- 150000001298 alcohols Chemical class 0.000 description 7
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- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 6
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- URLKBWYHVLBVBO-UHFFFAOYSA-N Para-Xylene Chemical group CC1=CC=C(C)C=C1 URLKBWYHVLBVBO-UHFFFAOYSA-N 0.000 description 6
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- 150000002170 ethers Chemical class 0.000 description 6
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 6
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- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 6
- 150000003377 silicon compounds Chemical class 0.000 description 6
- 239000000725 suspension Substances 0.000 description 6
- VOITXYVAKOUIBA-UHFFFAOYSA-N triethylaluminium Chemical compound CC[Al](CC)CC VOITXYVAKOUIBA-UHFFFAOYSA-N 0.000 description 6
- WKBOTKDWSSQWDR-UHFFFAOYSA-N Bromine atom Chemical compound [Br] WKBOTKDWSSQWDR-UHFFFAOYSA-N 0.000 description 5
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 5
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 5
- 229910052782 aluminium Inorganic materials 0.000 description 5
- 238000004458 analytical method Methods 0.000 description 5
- 238000012661 block copolymerization Methods 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 5
- 230000001186 cumulative effect Effects 0.000 description 5
- 125000002993 cycloalkylene group Chemical group 0.000 description 5
- 229910001873 dinitrogen Inorganic materials 0.000 description 5
- 238000004821 distillation Methods 0.000 description 5
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- 239000000706 filtrate Substances 0.000 description 5
- 150000004820 halides Chemical class 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- ZNQVEEAIQZEUHB-UHFFFAOYSA-N 2-ethoxyethanol Chemical compound CCOCCO ZNQVEEAIQZEUHB-UHFFFAOYSA-N 0.000 description 4
- 229940093475 2-ethoxyethanol Drugs 0.000 description 4
- OOBQBIQWXHFEJF-UHFFFAOYSA-N 2-ethoxyethyl phenyl carbonate Chemical compound CCOCCOC(=O)OC1=CC=CC=C1 OOBQBIQWXHFEJF-UHFFFAOYSA-N 0.000 description 4
- ZCYVEMRRCGMTRW-UHFFFAOYSA-N 7553-56-2 Chemical group [I] ZCYVEMRRCGMTRW-UHFFFAOYSA-N 0.000 description 4
- FHUODBDRWMIBQP-UHFFFAOYSA-N Ethyl p-anisate Chemical compound CCOC(=O)C1=CC=C(OC)C=C1 FHUODBDRWMIBQP-UHFFFAOYSA-N 0.000 description 4
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- 150000004945 aromatic hydrocarbons Chemical class 0.000 description 4
- 239000012298 atmosphere Substances 0.000 description 4
- GDTBXPJZTBHREO-UHFFFAOYSA-N bromine Substances BrBr GDTBXPJZTBHREO-UHFFFAOYSA-N 0.000 description 4
- 229910052794 bromium Inorganic materials 0.000 description 4
- DIOQZVSQGTUSAI-UHFFFAOYSA-N decane Chemical compound CCCCCCCCCC DIOQZVSQGTUSAI-UHFFFAOYSA-N 0.000 description 4
- USIUVYZYUHIAEV-UHFFFAOYSA-N diphenyl ether Chemical compound C=1C=CC=CC=1OC1=CC=CC=C1 USIUVYZYUHIAEV-UHFFFAOYSA-N 0.000 description 4
- 125000001033 ether group Chemical group 0.000 description 4
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- XDKQUSKHRIUJEO-UHFFFAOYSA-N magnesium;ethanolate Chemical compound [Mg+2].CC[O-].CC[O-] XDKQUSKHRIUJEO-UHFFFAOYSA-N 0.000 description 4
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 4
- 125000000740 n-pentyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 4
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 4
- 230000000379 polymerizing effect Effects 0.000 description 4
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- 125000003944 tolyl group Chemical group 0.000 description 4
- DURPTKYDGMDSBL-UHFFFAOYSA-N 1-butoxybutane Chemical compound CCCCOCCCC DURPTKYDGMDSBL-UHFFFAOYSA-N 0.000 description 3
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- TZCNHMLDUBDNQB-UHFFFAOYSA-N [2-(2-ethoxyethyl)-4-methylphenyl] hydrogen carbonate Chemical compound CCOCCC1=CC(C)=CC=C1OC(O)=O TZCNHMLDUBDNQB-UHFFFAOYSA-N 0.000 description 3
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- NIXFNZVGGMZGPZ-UHFFFAOYSA-N diethyl 2,2-bis(2-methylpropyl)propanedioate Chemical compound CCOC(=O)C(CC(C)C)(CC(C)C)C(=O)OCC NIXFNZVGGMZGPZ-UHFFFAOYSA-N 0.000 description 3
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- 238000001914 filtration Methods 0.000 description 3
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- 229910052731 fluorine Inorganic materials 0.000 description 3
- 150000002366 halogen compounds Chemical class 0.000 description 3
- 239000011630 iodine Substances 0.000 description 3
- 229910052740 iodine Inorganic materials 0.000 description 3
- 125000000959 isobutyl group Chemical group [H]C([H])([H])C([H])(C([H])([H])[H])C([H])([H])* 0.000 description 3
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- 150000002576 ketones Chemical class 0.000 description 1
- 239000006166 lysate Substances 0.000 description 1
- 150000002680 magnesium Chemical class 0.000 description 1
- 235000019359 magnesium stearate Nutrition 0.000 description 1
- HFTSQAKJLBPKBD-UHFFFAOYSA-N magnesium;butan-1-olate Chemical compound [Mg+2].CCCC[O-].CCCC[O-] HFTSQAKJLBPKBD-UHFFFAOYSA-N 0.000 description 1
- CCLBJCVPJCHEQD-UHFFFAOYSA-N magnesium;ethanolate;propan-1-olate Chemical compound [Mg+2].CC[O-].CCC[O-] CCLBJCVPJCHEQD-UHFFFAOYSA-N 0.000 description 1
- CRGZYKWWYNQGEC-UHFFFAOYSA-N magnesium;methanolate Chemical compound [Mg+2].[O-]C.[O-]C CRGZYKWWYNQGEC-UHFFFAOYSA-N 0.000 description 1
- WNJYXPXGUGOGBO-UHFFFAOYSA-N magnesium;propan-1-olate Chemical compound CCCO[Mg]OCCC WNJYXPXGUGOGBO-UHFFFAOYSA-N 0.000 description 1
- 150000002736 metal compounds Chemical class 0.000 description 1
- QZCOACXZLDQHLQ-UHFFFAOYSA-M methanolate titanium(4+) chloride Chemical compound [Cl-].[Ti+4].[O-]C.[O-]C.[O-]C QZCOACXZLDQHLQ-UHFFFAOYSA-M 0.000 description 1
- OKENUZUGNVCOMC-UHFFFAOYSA-K methanolate titanium(4+) trichloride Chemical compound [Cl-].[Cl-].[Cl-].CO[Ti+3] OKENUZUGNVCOMC-UHFFFAOYSA-K 0.000 description 1
- UZKWTJUDCOPSNM-UHFFFAOYSA-N methoxybenzene Substances CCCCOC=C UZKWTJUDCOPSNM-UHFFFAOYSA-N 0.000 description 1
- 125000004184 methoxymethyl group Chemical group [H]C([H])([H])OC([H])([H])* 0.000 description 1
- WQRQRJJICXLFKF-UHFFFAOYSA-N methyl 2-phenylmethoxyethyl carbonate Chemical compound COC(=O)OCCOCC1=CC=CC=C1 WQRQRJJICXLFKF-UHFFFAOYSA-N 0.000 description 1
- GMCCFGIAFMMJPF-UHFFFAOYSA-N methyl 2-propoxyethyl carbonate Chemical compound CCCOCCOC(=O)OC GMCCFGIAFMMJPF-UHFFFAOYSA-N 0.000 description 1
- QSSJZLPUHJDYKF-UHFFFAOYSA-N methyl 4-methylbenzoate Chemical compound COC(=O)C1=CC=C(C)C=C1 QSSJZLPUHJDYKF-UHFFFAOYSA-N 0.000 description 1
- STZCRXQWRGQSJD-GEEYTBSJSA-M methyl orange Chemical compound [Na+].C1=CC(N(C)C)=CC=C1\N=N\C1=CC=C(S([O-])(=O)=O)C=C1 STZCRXQWRGQSJD-GEEYTBSJSA-M 0.000 description 1
- 229940012189 methyl orange Drugs 0.000 description 1
- DDIZAANNODHTRB-UHFFFAOYSA-N methyl p-anisate Chemical compound COC(=O)C1=CC=C(OC)C=C1 DDIZAANNODHTRB-UHFFFAOYSA-N 0.000 description 1
- XJRBAMWJDBPFIM-UHFFFAOYSA-N methyl vinyl ether Chemical group COC=C XJRBAMWJDBPFIM-UHFFFAOYSA-N 0.000 description 1
- DRXHEPWCWBIQFJ-UHFFFAOYSA-N methyl(triphenoxy)silane Chemical compound C=1C=CC=CC=1O[Si](OC=1C=CC=CC=1)(C)OC1=CC=CC=C1 DRXHEPWCWBIQFJ-UHFFFAOYSA-N 0.000 description 1
- JFCCVNTYPIUJDJ-UHFFFAOYSA-N methyl-tris(prop-2-enyl)silane Chemical compound C=CC[Si](C)(CC=C)CC=C JFCCVNTYPIUJDJ-UHFFFAOYSA-N 0.000 description 1
- NINOYJQVULROET-UHFFFAOYSA-N n,n-dimethylethenamine Chemical group CN(C)C=C NINOYJQVULROET-UHFFFAOYSA-N 0.000 description 1
- WRUFJVBJAJAEPL-UHFFFAOYSA-N n-[(cyclohexylamino)-dimethoxysilyl]cyclohexanamine Chemical compound C1CCCCC1N[Si](OC)(OC)NC1CCCCC1 WRUFJVBJAJAEPL-UHFFFAOYSA-N 0.000 description 1
- NMTAMKZOXOXJQJ-UHFFFAOYSA-N n-[ethyl-(ethylamino)-methylsilyl]ethanamine Chemical compound CCN[Si](C)(CC)NCC NMTAMKZOXOXJQJ-UHFFFAOYSA-N 0.000 description 1
- QAQDIBPVZJKPJK-UHFFFAOYSA-N n-[tert-butyl-(ethylamino)-methylsilyl]ethanamine Chemical compound CCN[Si](C)(C(C)(C)C)NCC QAQDIBPVZJKPJK-UHFFFAOYSA-N 0.000 description 1
- 125000006606 n-butoxy group Chemical group 0.000 description 1
- IQFXJRXOTKFGPN-UHFFFAOYSA-N n-ethenyl-n-ethylethanamine Chemical group CCN(CC)C=C IQFXJRXOTKFGPN-UHFFFAOYSA-N 0.000 description 1
- UIKLFEQVPMEVFM-UHFFFAOYSA-N n-methyl-n-[methyl-bis(methylamino)silyl]cyclopentanamine Chemical compound CN[Si](C)(NC)N(C)C1CCCC1 UIKLFEQVPMEVFM-UHFFFAOYSA-N 0.000 description 1
- 238000006386 neutralization reaction Methods 0.000 description 1
- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen group Chemical group [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 description 1
- 125000001400 nonyl group Chemical class [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 125000003518 norbornenyl group Chemical group C12(C=CC(CC1)C2)* 0.000 description 1
- HMMGMWAXVFQUOA-UHFFFAOYSA-N octamethylcyclotetrasiloxane Chemical compound C[Si]1(C)O[Si](C)(C)O[Si](C)(C)O[Si](C)(C)O1 HMMGMWAXVFQUOA-UHFFFAOYSA-N 0.000 description 1
- 229940055577 oleyl alcohol Drugs 0.000 description 1
- XMLQWXUVTXCDDL-UHFFFAOYSA-N oleyl alcohol Natural products CCCCCCC=CCCCCCCCCCCO XMLQWXUVTXCDDL-UHFFFAOYSA-N 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- 150000002894 organic compounds Chemical class 0.000 description 1
- 239000012044 organic layer Substances 0.000 description 1
- NFHFRUOZVGFOOS-UHFFFAOYSA-N palladium;triphenylphosphane Chemical compound [Pd].C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1 NFHFRUOZVGFOOS-UHFFFAOYSA-N 0.000 description 1
- 125000004817 pentamethylene group Chemical group [H]C([H])([*:2])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[*:1] 0.000 description 1
- 125000000951 phenoxy group Chemical group [H]C1=C([H])C([H])=C(O*)C([H])=C1[H] 0.000 description 1
- XNWXGCFCRLGREZ-UHFFFAOYSA-N phenyl 2-phenylmethoxyethyl carbonate Chemical compound C=1C=CC=CC=1OC(=O)OCCOCC1=CC=CC=C1 XNWXGCFCRLGREZ-UHFFFAOYSA-N 0.000 description 1
- GQZHOAXMLUWGPO-UHFFFAOYSA-N phenyl 2-propoxyethyl carbonate Chemical compound C(OCCOCCC)(OC1=CC=CC=C1)=O GQZHOAXMLUWGPO-UHFFFAOYSA-N 0.000 description 1
- ABKQKGWNUKXYRV-UHFFFAOYSA-N phenyl 2-propoxypropyl carbonate Chemical compound C(OCC(C)OCCC)(OC1=CC=CC=C1)=O ABKQKGWNUKXYRV-UHFFFAOYSA-N 0.000 description 1
- AHWALFGBDFAJAI-UHFFFAOYSA-N phenyl carbonochloridate Chemical compound ClC(=O)OC1=CC=CC=C1 AHWALFGBDFAJAI-UHFFFAOYSA-N 0.000 description 1
- WVDDGKGOMKODPV-ZQBYOMGUSA-N phenyl(114C)methanol Chemical compound O[14CH2]C1=CC=CC=C1 WVDDGKGOMKODPV-ZQBYOMGUSA-N 0.000 description 1
- 125000000843 phenylene group Chemical group C1(=C(C=CC=C1)*)* 0.000 description 1
- 229940067107 phenylethyl alcohol Drugs 0.000 description 1
- FVZVCSNXTFCBQU-UHFFFAOYSA-N phosphanyl Chemical group [PH2] FVZVCSNXTFCBQU-UHFFFAOYSA-N 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-N phosphoric acid Substances OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- NAYYNDKKHOIIOD-UHFFFAOYSA-N phthalamide Chemical compound NC(=O)C1=CC=CC=C1C(N)=O NAYYNDKKHOIIOD-UHFFFAOYSA-N 0.000 description 1
- 125000003367 polycyclic group Chemical group 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920005629 polypropylene homopolymer Polymers 0.000 description 1
- 229920005630 polypropylene random copolymer Polymers 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 125000006410 propenylene group Chemical group 0.000 description 1
- 125000006225 propoxyethyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])OC([H])([H])C([H])([H])* 0.000 description 1
- 125000005767 propoxymethyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])[#8]C([H])([H])* 0.000 description 1
- 125000006235 propyl amino ethyl group Chemical group [H]N(C([H])([H])C([H])([H])*)C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- FOWDZVNRQHPXDO-UHFFFAOYSA-N propyl hydrogen carbonate Chemical compound CCCOC(O)=O FOWDZVNRQHPXDO-UHFFFAOYSA-N 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000010517 secondary reaction Methods 0.000 description 1
- AIFMYMZGQVTROK-UHFFFAOYSA-N silicon tetrabromide Chemical compound Br[Si](Br)(Br)Br AIFMYMZGQVTROK-UHFFFAOYSA-N 0.000 description 1
- FDNAPBUWERUEDA-UHFFFAOYSA-N silicon tetrachloride Chemical compound Cl[Si](Cl)(Cl)Cl FDNAPBUWERUEDA-UHFFFAOYSA-N 0.000 description 1
- 229920002545 silicone oil Polymers 0.000 description 1
- 125000004469 siloxy group Chemical group [SiH3]O* 0.000 description 1
- 125000005353 silylalkyl group Chemical class 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 238000007613 slurry method Methods 0.000 description 1
- 229910000030 sodium bicarbonate Inorganic materials 0.000 description 1
- 235000017557 sodium bicarbonate Nutrition 0.000 description 1
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 239000012086 standard solution Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 125000005346 substituted cycloalkyl group Chemical group 0.000 description 1
- 239000001384 succinic acid Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 229920001897 terpolymer Polymers 0.000 description 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- UTADZBVVSYSYTG-UHFFFAOYSA-N tert-butyl(methyl)silane Chemical compound C[SiH2]C(C)(C)C UTADZBVVSYSYTG-UHFFFAOYSA-N 0.000 description 1
- HXLWJGIPGJFBEZ-UHFFFAOYSA-N tert-butyl(trimethoxy)silane Chemical compound CO[Si](OC)(OC)C(C)(C)C HXLWJGIPGJFBEZ-UHFFFAOYSA-N 0.000 description 1
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 description 1
- ADLSSRLDGACTEX-UHFFFAOYSA-N tetraphenyl silicate Chemical compound C=1C=CC=CC=1O[Si](OC=1C=CC=CC=1)(OC=1C=CC=CC=1)OC1=CC=CC=C1 ADLSSRLDGACTEX-UHFFFAOYSA-N 0.000 description 1
- XROWMBWRMNHXMF-UHFFFAOYSA-J titanium tetrafluoride Chemical compound [F-].[F-].[F-].[F-].[Ti+4] XROWMBWRMNHXMF-UHFFFAOYSA-J 0.000 description 1
- VXUYXOFXAQZZMF-UHFFFAOYSA-N titanium(IV) isopropoxide Chemical compound CC(C)O[Ti](OC(C)C)(OC(C)C)OC(C)C VXUYXOFXAQZZMF-UHFFFAOYSA-N 0.000 description 1
- YONPGGFAJWQGJC-UHFFFAOYSA-K titanium(iii) chloride Chemical compound Cl[Ti](Cl)Cl YONPGGFAJWQGJC-UHFFFAOYSA-K 0.000 description 1
- 238000006276 transfer reaction Methods 0.000 description 1
- VALAJCQQJWINGW-UHFFFAOYSA-N tri(propan-2-yl)alumane Chemical compound CC(C)[Al](C(C)C)C(C)C VALAJCQQJWINGW-UHFFFAOYSA-N 0.000 description 1
- RYFIHIMBHQWVNQ-UHFFFAOYSA-N tributoxy(chloro)silane Chemical compound CCCCO[Si](Cl)(OCCCC)OCCCC RYFIHIMBHQWVNQ-UHFFFAOYSA-N 0.000 description 1
- SELBPKHVKHQTIB-UHFFFAOYSA-N trichloro(ethoxy)silane Chemical compound CCO[Si](Cl)(Cl)Cl SELBPKHVKHQTIB-UHFFFAOYSA-N 0.000 description 1
- IORQPMCLCHBYMP-UHFFFAOYSA-N trichloro(methoxy)silane Chemical compound CO[Si](Cl)(Cl)Cl IORQPMCLCHBYMP-UHFFFAOYSA-N 0.000 description 1
- KOSDRGGXVCAXGC-UHFFFAOYSA-N trichloro(propoxy)silane Chemical compound CCCO[Si](Cl)(Cl)Cl KOSDRGGXVCAXGC-UHFFFAOYSA-N 0.000 description 1
- GYLIOGDFGLKMOL-UHFFFAOYSA-N trichloromethanol Chemical compound OC(Cl)(Cl)Cl GYLIOGDFGLKMOL-UHFFFAOYSA-N 0.000 description 1
- SVGQCVJXVAMCPM-UHFFFAOYSA-N triethyl(prop-2-enyl)silane Chemical compound CC[Si](CC)(CC)CC=C SVGQCVJXVAMCPM-UHFFFAOYSA-N 0.000 description 1
- WILBTFWIBAOWLN-UHFFFAOYSA-N triethyl(triethylsilyloxy)silane Chemical compound CC[Si](CC)(CC)O[Si](CC)(CC)CC WILBTFWIBAOWLN-UHFFFAOYSA-N 0.000 description 1
- ORYGRKHDLWYTKX-UHFFFAOYSA-N trihexylalumane Chemical compound CCCCCC[Al](CCCCCC)CCCCCC ORYGRKHDLWYTKX-UHFFFAOYSA-N 0.000 description 1
- DSNMSIRQEQAGHB-UHFFFAOYSA-N trimethyl(2-trimethylsilyloxyethenoxy)silane Chemical group C[Si](C)(C)OC=CO[Si](C)(C)C DSNMSIRQEQAGHB-UHFFFAOYSA-N 0.000 description 1
- AMGXUPKDZBCKPF-BQYQJAHWSA-N trimethyl-[(e)-2-trimethylsilylethenyl]silane Chemical group C[Si](C)(C)\C=C\[Si](C)(C)C AMGXUPKDZBCKPF-BQYQJAHWSA-N 0.000 description 1
- 125000003258 trimethylene group Chemical group [H]C([H])([*:2])C([H])([H])C([H])([H])[*:1] 0.000 description 1
- 125000000026 trimethylsilyl group Chemical group [H]C([H])([H])[Si]([*])(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- KHQZLUVCZCAMFU-UHFFFAOYSA-N tripropyl(tripropylsilyloxy)silane Chemical compound CCC[Si](CCC)(CCC)O[Si](CCC)(CCC)CCC KHQZLUVCZCAMFU-UHFFFAOYSA-N 0.000 description 1
- 125000002948 undecyl group Chemical class [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 239000012808 vapor phase Substances 0.000 description 1
- UKRDPEFKFJNXQM-UHFFFAOYSA-N vinylsilane Chemical compound [SiH3]C=C UKRDPEFKFJNXQM-UHFFFAOYSA-N 0.000 description 1
- 125000005023 xylyl group Chemical group 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
- C08F210/04—Monomers containing three or four carbon atoms
- C08F210/06—Propene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F297/00—Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer
- C08F297/06—Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer using a catalyst of the coordination type
- C08F297/08—Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer using a catalyst of the coordination type polymerising mono-olefins
Definitions
- the present invention when copolymerizing propylene and ethylene or propylene and ⁇ -olefin, by using a polymerization catalyst that is excellent in copolymerization characteristics of the rubber component in the latter stage of multistage polymerization and can introduce a large amount of good quality rubber,
- the present invention relates to a method for producing a propylene-based block copolymer having an excellent balance between rigidity and impact resistance.
- olefins such as propylene have been polymerized by using an olefin polymerization catalyst.
- homopolymerization of propylene or random copolymerization of propylene and a small amount of ethylene is performed in the former stage, and in the latter stage.
- a propylene block copolymer obtained by copolymerizing propylene and ethylene or propylene and ⁇ -olefin is melted and then molded by various molding machines, stretching machines, etc., and is then used for automobile parts and household appliance parts.
- molded products such as containers, they are used in various applications such as containers and sheets.
- propylene-ethylene block copolymers have good mechanical properties such as rigidity and heat resistance, and can be produced at a relatively low cost, so that they are used in a wide range of applications.
- Solid catalyst components containing magnesium, titanium, an electron donating compound and halogen atoms as essential components are known as constituents of the olefin polymerization catalyst, and the solid catalyst component, organoaluminum compound, and organosilicon compound are known.
- Many catalysts for olefin polymerization comprising
- propylene-based block copolymers are preferably used is that the balance between rigidity and impact resistance is excellent.
- the olefin polymerization catalyst is capable of producing polypropylene with high stereoregularity, and because the impact strength is high, the copolymerization activity in the latter stage is high and a predetermined amount is required. It is required that the above copolymer can be produced, and at the same time, the obtained copolymer has high randomness, high polymerization activity sustainability, and excellent polymerization reaction control characteristics.
- the propylene block copolymer means a blend of a polymer component mainly composed of propylene and a random copolymer component of propylene and an ⁇ -olefin monomer such as ethylene, and generally corresponds to each component.
- a so-called multistage polymerization technique in which the respective components are blended in a reactor.
- One typical application of the propylene-based block copolymer is an injection molding application such as an automobile bumper.
- MFR melt flow rate
- the MFR of the propylene block copolymer is the MFR of the polymer component made of propylene, the MFR of the random copolymer component of propylene and an ⁇ -olefin monomer such as ethylene, and the random copolymer component in the block copolymer It is uniquely determined by the three elements of the content.
- the MFR of the random copolymer component and the content of the random copolymer component In order to maintain high quality, it is required that an ⁇ -olefin, particularly ethylene, is effectively introduced into the random copolymerization part and that the crystalline polyethylene is relatively small.
- the impact resistance strength which is one of the physical properties required for injection molding applications, be improved especially at low temperature impact strength when used for automobile bumpers and the like. Since the low temperature impact strength depends on the embrittlement temperature of the random copolymer component, if the propylene content in the random copolymer component is too high, the embrittlement temperature becomes high and the low temperature impact strength is insufficient. In order to increase the low temperature impact strength, it is necessary to lower the embrittlement temperature of the random copolymer component, and for this purpose, the content of ⁇ -olefin such as ethylene in the random copolymer component should be increased. Is preferred.
- a polymer component (a) mainly composed of propylene is produced in the first polymerization step, and propylene and an ⁇ -olefin such as ethylene are produced in the second polymerization step. It is common to produce random copolymer component (b).
- a polymer component (a) mainly composed of propylene is produced in the first polymerization step, and propylene and an ⁇ -olefin such as ethylene are produced in the second polymerization step. It is common to produce random copolymer component (b).
- the dispersion of the activity of the polymer particles entering the second polymerization step becomes large due to the wide distribution of the residence time, and the random copolymer component is excessively produced in the second polymerization step. This is thought to be due to the increase in particles. For this reason, the polymer particles entering the second polymerization step have a high activity in polymerizing the random copolymer component, and there is a demand for a production method in which the residence time is short and consequently the residence time distribution is narrow. Therefore, the catalyst for propylene block copolymer is desired to have a relatively high random copolymer activity.
- Patent Document 1 a method using a catalyst in which hydrogen halide is improved by using aluminum halide at the time of producing a solid catalyst
- Patent Document 2 a method using an organosilicon compound having an amino group
- Patent Documents 3 to 5 a method using an organosilicon compound having an amino group
- the olefin polymerization catalyst described in Patent Document 1 exhibits good hydrogen-to-hydrogen activity as compared with conventional polymerization catalysts, and the olefin polymer obtained using such a solid catalyst component is a molten polymer. It has a high fluidity (MFR) and is particularly useful when producing large molded articles by injection molding or the like.
- MFR fluidity
- the activity of the random copolymer part and a catalyst capable of efficiently incorporating ethylene into the random copolymer part have not yet been obtained.
- a method for solving the copolymerization problem of ethylene a method using a titanium compound having a Ti—N bond (see, for example, Patent Document 6), an organosilicon compound and a saturated hydrocarbon during the second stage polymerization. (For example, refer patent document 7) etc. are proposed. However, there is still room for improvement in the copolymerization performance.
- JP 2012-214556 A JP-A-8-67710 JP-A-8-3215 JP 2004-315742 A JP 2005-48045 A JP-A-6-228223 JP-A-9-87329
- an object of the present invention is to provide a method for producing a propylene-based block copolymer having a high rubber content and a high ⁇ -olefin such as ethylene and having an excellent balance between rigidity and impact resistance.
- the present inventors have conducted intensive studies, and as a result, used a copolymerization catalyst having a solid catalyst component containing a compound having magnesium, titanium, halogen, a specific ether group and a carbonate group as essential constituent requirements.
- the inventors have found that the above object can be achieved by copolymerization, and have completed the present invention.
- the present invention relates to (I) titanium, magnesium, halogen and the following general formula (1); R 1 O—C ( ⁇ O) —O—Z—OR 2 (1) (Wherein R 1 and R 2 are a linear alkyl group having 1 to 20 carbon atoms, a branched alkyl group having 3 to 20 carbon atoms, a vinyl group, a linear alkenyl group having 3 to 20 carbon atoms, or a branched alkenyl group.
- a linear halogen-substituted alkyl group having 1 to 20 carbon atoms a branched halogen-substituted alkyl group having 3 to 20 carbon atoms, a linear halogen-substituted alkenyl group having 2 to 20 carbon atoms, and a branched halogen having 3 to 20 carbon atoms
- a propylene block copolymer having high rigidity and high impact resistance can be obtained in high yield.
- the solid catalyst component for copolymerization used in the method for producing a propylene-based block copolymer of the present invention is magnesium, titanium, halogen, and electron donating property.
- the compound contains an electron donating compound represented by the above general formula (1) (hereinafter sometimes simply referred to as “component (A)”) as an essential component.
- halogen examples include fluorine, chlorine, bromine and iodine atoms, among which chlorine, bromine and iodine are preferable, and chlorine and iodine are particularly preferable.
- Examples of the linear alkyl group having 1 to 20 carbon atoms of R 1 and R 2 in the general formula (1) include, for example, a methyl group, an ethyl group, an n-propyl group, an n-butyl group, an n-pentyl group, Examples include n-hexyl group, n-pentyl group, n-octyl group, n-nonyl group, n-decyl group and the like.
- a linear alkyl group having 1 to 12 carbon atoms is preferred.
- Examples of the branched alkyl group having 3 to 20 carbon atoms of R 1 and R 2 include alkyl having a secondary carbon or tertiary carbon such as isopropyl group, isobutyl group, t-butyl group, isopentyl group and neopentyl group. Groups. A branched alkyl group having 3 to 12 carbon atoms is preferred.
- Examples of the linear alkenyl group having 3 to 20 carbon atoms of R 1 and R 2 include an allyl group, a 3-butenyl group, a 4-hexenyl group, a 5-hexenyl group, a 7-octenyl group, and a 10-dodecenyl group. Etc. A straight-chain alkenyl group having 3 to 12 carbon atoms is preferred. Examples of the branched alkenyl group having 3 to 20 carbon atoms include isopropenyl group, isobutenyl group, isopentenyl group, 2-ethyl-3-hexenyl group and the like. A branched alkenyl group having 3 to 12 carbon atoms is preferred.
- Examples of the linear halogen-substituted alkyl group having 1 to 20 carbon atoms of R 1 and R 2 include a halogenated methyl group, a halogenated ethyl group, a halogenated n-propyl group, a halogenated n-butyl group, Halogenated n-pentyl group, halogenated n-hexyl group, halogenated n-pentyl group, halogenated n-octyl group, halogenated nonyl group, halogenated decyl group, halogen-substituted undecyl group, halogen-substituted dodecyl group, etc. It is done.
- a linear halogen-substituted alkyl group having 1 to 12 carbon atoms is preferable.
- the branched halogen-substituted alkyl group having 3 to 20 carbon atoms include a halogenated isopropyl group, a halogenated isobutyl group, a halogenated 2-ethylhexyl group, and a halogenated neopentyl group.
- a branched halogen-substituted alkyl group having 3 to 12 carbon atoms is preferable.
- Examples of the linear halogen-substituted alkenyl group having 2 to 20 carbon atoms of R 1 and R 2 include a 2-halogenated vinyl group, a 3-halogenated allyl group, a 3-halogenated-2-butenyl group, Examples include 4-halogenated-3-butenyl group, perhalogenated-2-butenyl group, 6-halogenated-4-hexenyl group, and 3-trihalogenated methyl-2-propenyl group.
- a halogen-substituted alkenyl group having 2 to 12 carbon atoms is preferred.
- Examples of the branched halogen-substituted alkenyl group having 3 to 20 carbon atoms include 3-trihalogenated-2-butenyl group, 2-pentahalogenated ethyl-3-hexenyl group, and 6-halogenated-3-ethyl-4- Examples include a hexenyl group and a 3-halogenated isobutenyl group.
- a branched halogen-substituted alkenyl group having 3 to 12 carbon atoms is preferred.
- Examples of the cycloalkyl group having 3 to 20 carbon atoms of R 1 and R 2 include cyclopropyl group, cyclobutyl group, cyclopentyl group, tetramethylcyclopentyl group, cyclohexyl group, methylcyclohexyl group, cycloheptyl group, and cyclooctyl group. , Cyclononyl group, cyclodecyl group, butylcyclopentyl group and the like. A cycloalkyl group having 3 to 12 carbon atoms is preferred.
- Examples of the C3-C20 cycloalkenyl group include a cyclopropenyl group, a cyclopentenyl group, a cyclohexenyl group, a cyclooctenyl group, and a norbornene group.
- a cycloalkenyl group having 3 to 12 carbon atoms is preferred.
- halogen-substituted cycloalkyl group having 3 to 20 carbon atoms of R 1 and R 2 examples include a halogen-substituted cyclopropyl group, a halogen-substituted cyclobutyl group, a halogen-substituted cyclopentyl group, a halogen-substituted trimethylcyclopentyl group, a halogen-substituted cyclohexyl group, Examples include halogen-substituted methylcyclohexyl group, halogen-substituted cycloheptyl group, halogen-substituted cyclooctyl group, halogen-substituted cyclononyl group, halogen-substituted cyclodecyl group, and halogen-substituted butylcyclopentyl group.
- Examples of the halogen-substituted cycloalkenyl group having 3 to 20 carbon atoms of R 1 and R 2 include a halogen-substituted cyclopropenyl group, a halogen-substituted cyclobutenyl group, a halogen-substituted cyclopentenyl group, a halogen-substituted trimethylcyclopentenyl group, and a halogen-substituted cycloalkenyl group.
- Examples include a hexenyl group, a halogen-substituted methylcyclohexenyl group, a halogen-substituted cycloheptenyl group, a halogen-substituted cyclooctenyl group, a halogen-substituted cyclononenyl group, a halogen-substituted cyclodecenyl group, and a halogen-substituted butylcyclopentenyl group.
- a halogen-substituted cycloalkenyl group having 3 to 12 carbon atoms is preferred.
- Examples of the aromatic hydrocarbon group having 6 to 24 carbon atoms of R 1 and R 2 include phenyl group, methylphenyl group, dimethylphenyl group, ethylphenyl group, benzyl group, 1-phenylethyl group, 2-phenyl group.
- Examples include an ethyl group, a 2-phenylpropyl group, a 1-phenylbutyl group, a 4-phenylbutyl group, a 2-phenylheptyl group, a tolyl group, a xylyl group, a naphthyl group, and a 1,8-dimethylnaphthyl group.
- An aromatic hydrocarbon group having 6 to 12 carbon atoms is preferred.
- Examples of the halogen-substituted aromatic hydrocarbon group having 6 to 24 carbon atoms of R 1 and R 2 include a halogenated phenyl group, a halogenated methylphenyl group, a trihalogenated methylphenyl group, a perhalogenated benzyl group, a perhalogenated group. Examples thereof include a halogenated phenyl group, a 2-phenyl-2-halogenated ethyl group, a perhalogenated naphthyl group, and a 4-phenyl-2,3-dihalogenated butyl group.
- a halogen-substituted aromatic hydrocarbon group having 6 to 12 carbon atoms is preferred.
- halogen substituted alkyl group halogen substituted alkenyl group, halogen substituted cycloalkyl group, halogen substituted cycloalkenyl group, and halogen substituted aromatic hydrocarbon group of R 1 and R 2 , as the halogen species, fluorine, chlorine, Examples thereof include bromine and iodine, preferably fluorine, chlorine or bromine.
- the nitrogen atom-containing hydrocarbon group having 2 to 24 carbon atoms excluding those in which the bond terminal of R 1 and R 2 is a C ⁇ N group is a group in which the bond terminal is a carbon atom.
- the oxygen atom-containing hydrocarbon group having 2 to 24 carbon atoms is a group in which the bond ends are carbon atoms, such as a methoxymethyl group, Ethers such as ethoxymethyl group, propoxymethyl group, butoxymethyl group, isopropoxymethyl group, isobutoxymethyl group, methoxyethyl group, ethoxyethyl group, propoxyethyl group, butoxyethyl group, isopropoxyethyl group, isobutoxyethyl group Group-containing hydrocarbon groups, phenoxymethyl groups, methylphenoxymethyl groups, dimethylphenoxymethyl groups, aryloxyalkyl groups such as naphthoxymethyl groups, alkoxyaryl groups such as methoxyphenyl groups and ethoxyphenyl groups, and acetoxymethyl groups It is done.
- An oxygen atom-containing hydrocarbon group having 2 to 12 carbon atoms is preferred.
- the phosphorus-containing hydrocarbon group excluding those in which the bond terminal of 2 to 24 carbon atoms of R 1 and R 2 is a C ⁇ P group is a group in which the bond terminal is a carbon atom.
- Dialkylphosphinoalkyl groups such as finomethyl group, dibutylphosphinomethyl group, dicyclohexylphosphinomethyl group, dimethylphosphinoethyl group, dibutylphosphinoethyl group, dicyclohexylphosphinoethyl group, diphenylphosphinomethyl group, ditolylphosphine
- diarylphosphinoalkyl groups such as finomethyl groups, phosphino group-substituted aryl groups such as dimethylphosphinophenyl groups, and diethylphosphinophenyl groups.
- a phosphorus-containing hydrocarbon group having 2 to 12 carbon atoms is preferred.
- the bond terminal means an
- Examples of the silicon-containing hydrocarbon group having 1 to 24 carbon atoms of R 1 and R 2 include a hydrocarbon-substituted silyl group, a hydrocarbon-substituted siloxyalkyl group, a hydrocarbon-substituted silylalkyl group, and a hydrocarbon-substituted silylaryl group.
- hydrocarbon-substituted silyl such as phenylsilyl, diphenylsilyl, trimethylsilyl, triethylsilyl, tripropylsilyl, tricyclohexylsilyl, triphenylsilyl, methyldiphenylsilyl, tolylsilyl, trinaphthylsilyl, etc.
- siloxy hydrocarbon groups such as trimethylsiloxymethyl group, trimethylsiloxyethyl group, trimethylsiloxyphenyl group, hydrocarbon-substituted silyl ether groups such as trimethylsilyl ether, silicon-substituted alkyl groups such as trimethylsilylmethyl, trimethyl
- silicon-substituted aryl groups such as silyl phenyl and the like.
- a silicon-containing hydrocarbon group having 1 to 12 carbon atoms is preferable.
- R 1 Preferred groups among R 1 are linear alkyl groups having 1 to 12 carbon atoms, branched alkyl groups having 3 to 12 carbon atoms, vinyl groups, linear alkenyl groups or branched alkenyl groups having 3 to 12 carbon atoms, Straight chain halogen-substituted alkyl group having 1 to 12 carbon atoms, branched halogen-substituted alkyl group having 3 to 12 carbon atoms, straight-chain halogen-substituted alkenyl group or branched halogen-substituted alkenyl group having 3 to 12 carbon atoms, 3 to 3 carbon atoms 12 cycloalkyl groups, C 3-12 cycloalkenyl groups, C 3-12 halogen-substituted cycloalkyl groups, C 3-12 halogen-substituted cycloalkenyl groups, or C 6-12 aromatic carbonization.
- a hydrogen group, and more preferable groups are a linear alkyl group having 1 to 12 carbon atoms, a branched alkyl group having 3 to 12 carbon atoms, a vinyl group, and a linear alkyl group having 3 to 12 carbon atoms.
- Lucenyl group or branched alkenyl group linear halogen-substituted alkyl group having 1 to 12 carbon atoms, branched halogen-substituted alkyl group having 3 to 12 carbon atoms, cycloalkyl group having 3 to 12 carbon atoms, cyclohexane having 3 to 12 carbon atoms
- An alkenyl group or an aromatic hydrocarbon group having 6 to 12 carbon atoms, particularly preferred groups are linear alkyl groups having 1 to 12 carbon atoms, branched alkyl groups having 3 to 12 carbon atoms, and 6 to 6 carbon atoms. 12 aromatic hydrocarbon groups.
- R 2 is a linear alkyl group having 1 to 12 carbon atoms, a branched alkyl group having 3 to 12 carbon atoms whose bonding end is —CH 2 —, a vinyl group, or a straight chain having 3 to 12 carbon atoms.
- Z is a divalent linking group that binds a carbonate group and an ether group (OR 2 group).
- the two oxygen atoms to which Z is bound are bonded by a carbon chain, More preferably, it is a bonding group in which the carbon chain is composed of two carbon atoms.
- two Z's in a cyclic group such as a cycloalkylene group, a cycloalkenylene group, a halogen-substituted cycloalkylene group, a halogen-substituted cycloalkenylene group, an aromatic hydrocarbon group, or a halogen-substituted aromatic hydrocarbon group are bonded.
- Oxygen atoms are bonded by a carbon chain, and the bonding group in which the carbon chain is composed of two carbon atoms means that two adjacent carbon chains in the carbon chain constituting the ring are the Z Is a carbon chain between two bonded oxygen atoms.
- Z include a linear alkylene group having 1 to 20 carbon atoms, a branched alkylene group having 3 to 20 carbon atoms, a vinylene group, a linear alkenylene group or branched alkenylene group having 3 to 20 carbon atoms, 1 to 20 linear halogen-substituted alkylene group, 3 to 20 branched halogen-substituted alkylene group, 3 to 20 linear halogen-substituted alkenylene group or branched halogen-substituted alkenylene group, 3 to 20 carbon atoms
- Z are ethylene group having 2 carbon atoms, branched alkylene group having 3 to 12 carbon atoms, vinylene group, linear alkenylene group or branched alkenylene group having 3 to 12 carbon atoms, 12 linear halogen-substituted alkylene groups, 3 to 12 branched halogen-substituted alkylene groups, 3 to 12 straight-chain halogen-substituted alkenylene groups or branched halogen-substituted alkenylene groups, 3 to 12 cycloalkylenes Group, a C3-C12 cycloalkenylene group, a C3-C12 halogen-substituted cycloalkylene group, a C3-C12 halogen-substituted cycloalkenylene group, a C6-C12 aromatic hydrocarbon group, a carbon number 6-12 halogen-substituted aromatic hydrocarbon group, 2-12 carbon atom-containing hydrocarbon group
- linear alkylene group having 1 to 20 carbon atoms of Z examples include ethylene group, trimethylene group, tetramethylene group, pentamethylene group, hexamethylene group, heptamethylene group, octamethylene group, nonamethylene group, decamethylene group, unamethylene group, A decamethylene group, a dodecamethylene group, a tridecamethylene group, a tetradecamethylene group, etc. are mentioned.
- it is a linear alkylene group having 2 to 12 carbon atoms. More preferably, it is an ethylene group.
- Examples of the branched alkylene group having 3 to 20 carbon atoms of Z include 1-methylethylene group, 2-methyltrimethylene group, 2-methyltetramethylene group, 2-methylpentamethylene group, 3-methylhexamethylene group, 4 -Methylheptamethylene group, 4-methyloctamethylene group, 5-methylnonamethylene group, 5-methyldecamethylene group, 6-methylundecamethylene group, 7-methyldodecamethylene group, 7-methyltridecamethylene group, etc. Is mentioned.
- a branched alkylene group having 3 to 12 carbon atoms is preferable. More preferred are 1-methylethylene group, 2-methylethylene group and 1-ethylethylene group.
- Examples of the straight chain alkenylene group having 3 to 20 carbon atoms of Z include propenylene group, butenylene group, hexenylene group, octenylene group, octadecenylene group and the like.
- a linear alkenylene group having 3 to 12 carbon atoms is preferable.
- Examples of the branched alkenylene group having 3 to 20 carbon atoms of Z include isopropenylene group, 1-ethylethenylene group, 2-methylpropenylene group, 2,2-dimethylbutenylene group, and 3-methyl-2-butenylene group. 3-ethyl-2-butenylene group, 2-methyloctenylene group, 2,4-dimethyl-2-butenylene group and the like.
- the connecting part is a branched alkenylene group having 3 to 12 carbon atoms, which is an ethenylene group. More preferred are isopropenylene group and 1-ethylethenylene group.
- linear halogen-substituted alkenylene group having 1 to 20 carbon atoms of Z examples include a dichloroethenylene group, a difluoroethenylene group, a 3,3-dichloropropenylene group, and a 1,2-difluoropropenylene group. .
- a linear halogen-substituted alkenylene group having 3 to 12 carbon atoms is preferable.
- Examples of the branched halogen-substituted alkylene group having 1 to 20 carbon atoms of Z include 3,4-dichloro-1,2-butylene group, 2,2-dichloro-1,3-butylene group, 1,2-difluoro-1 , 2-propylene group and the like.
- a branched halogen-substituted alkylene group having 3 to 12 carbon atoms is preferable.
- Examples of the cycloalkylene group having 3 to 20 carbon atoms of Z include a cyclopentylene group, a cyclohexylene group, a cyclopropylene group, a 2-methylcyclopropylene group, a cyclobutylene group, a 2,2-dimethylcyclobutylene group, 2, Examples include 3-dimethylcyclopentylene group, 1,3,3-trimethylcyclohexylene group, cyclooctylene group and the like.
- a cycloalkylene group having 3 to 12 carbon atoms is preferable.
- Examples of the cycloalkenylene group having 3 to 20 carbon atoms of Z include a cyclopentenylene group, a 2,4-cyclopentadienylene group, a cyclohexenylene group, a 1,4-cyclohexadienylene group, and a cycloheptenylene.
- it is a C3-C12 cycloalkenylene group.
- Examples of the halogen-substituted cycloalkylene group having 3 to 20 carbon atoms of Z include a 3-chloro-1,2-cyclopentylene group, 3,4,5,6-tetrachloro-1,2-cyclohexylene group, 3 , 3-dichloro-1,2-cyclopropylene group, 2-chloromethylcyclopropylene group, 3,4-dichloro-1,2-cyclobutylene group, 3,3-bis (dichloromethyl) -1,2-cyclo Butylene group, 2,3-bis (dichloromethyl) cyclopentylene group, 1,3,3-tris (fluoromethyl) -1,2-cyclohexylene group, 3-trichloromethyl-1,2-cyclooctylene group Etc.
- a halogen-substituted cycloalkylene group having 3 to 12 carbon atoms is preferable.
- Examples of the halogen-substituted cycloalkenylene group having 3 to 20 carbon atoms of Z include a 5-chloro-1,2-cyclo-4-hexenylene group, 3,3,4,4-tetrafluoro-1,2-cyclo-6. -Octenylene group and the like.
- a halogen-substituted cycloalkenylene group having 3 to 12 carbon atoms is preferable.
- Examples of the aromatic hydrocarbon group having 6 to 24 carbon atoms of Z include 1,2-phenylene, 3-methyl-1,2-phenylene, 3,6-dimethyl-1,2-phenylene, and 1,2-naphthylene. 2,3-naphthylene, 5-methyl-1,2-naphthylene, 9,10-phenanthrylene, 1,2-anthracenylene and the like. Preferably, it is an aromatic hydrocarbon group having 6 to 12 carbon atoms.
- halogen-substituted aromatic hydrocarbon group having 6 to 24 carbon atoms of Z examples include 3-chloro-1,2-phenylene, 3-chloromethyl-1,2-phenylene, 3,6-dichloro-1,2- Phenylene, 3,6-dichloro-4,5-dimethyl-1,2-phenylene, 3-chloro-1,2-naphthylene, 3-fluoro-1,2-naphthylene, 3,6-dichloro-1,2- Phenylene, 3,6-difluoro-1,2-phenylene, 3,6-dibromo-1,2-phenylene, 1-chloro-2,3-naphthylene, 5-chloro-1,2-naphthylene, 2,6- Examples include dichloro-9,10-phenanthrylene, 5,6-dichloro-1,2-anthracenylene, 5,6-difluoro-1,2-anthracenylene, and the like.
- Examples of the nitrogen atom-containing hydrocarbon group having 1 to 24 carbon atoms of Z include 1-dimethylaminoethylene group, 1,2-bisdimethylminoethylene group, 1-diethylaminoethylene group, 2-diethylamino-1,3-propylene. Group, 2-ethylamino-1,3-propylene group, 4-dimethylamino-1,2-phenylene group, 4,5-bis (dimethylamino) phenylene group and the like.
- a nitrogen atom-containing hydrocarbon group having 2 to 12 carbon atoms is preferable.
- Examples of the oxygen atom-containing hydrocarbon group having 1 to 24 carbon atoms of Z include 1-methoxyethylene group, 2,2-dimethoxy-1,3-propanylene group, 2-ethoxy-1,3-propanylene group, 2- Examples thereof include t-butoxy-1,3-propanylene group, 2,3-dimethoxy-2,3-butylene group, 4-methoxy-1,2-phenylene group and the like.
- An oxygen atom-containing hydrocarbon group having 2 to 12 carbon atoms is preferable.
- Examples of the phosphorus-containing hydrocarbon group having 1 to 24 carbon atoms of Z include 1-dimethylphosphinoethylene group, 2,2-bis (dimethylphosphino) -1,3-propanylene group, 2-diethylphosphino-1 , 3-propanylene group, 2-t-butoxymethylphosphino-1,3-propanylene group, 2,3-bis (diphenylphosphino) -2,3-butylene group, 4-methylphosphate-1,2- Examples include a phenylene group. Preferably, it is a phosphorus-containing hydrocarbon group having 1 to 12 carbon atoms.
- Examples of the silicon-containing hydrocarbon group having 1 to 24 carbon atoms of Z include trimethylsilylethylene group, 1,2-bis (trimethylsilyl) ethylene group, 1,2-bis (trimethylsiloxy) ethylene group, 2,2-bis ( 4-trimethylsilylphenyl) -1,3-propanylene group, 1,2-bis (monomethylsilane) -ethylene group and the like.
- a silicon-containing hydrocarbon group having 1 to 12 carbon atoms is preferable.
- Specific examples of the compound represented by the general formula (I) include 2-methoxyethyl methyl carbonate, 2-ethoxyethyl methyl carbonate, 2-propoxyethyl methyl carbonate, 2-butoxyethyl methyl carbonate, 2- (2-ethoxy Ethyloxy) ethyl methyl carbonate, 2-benzyloxyethyl methyl carbonate, (2-methoxypropyl) methyl carbonate, 2-ethoxypropyl methyl carbonate, 2-methyl (2-methoxy) butyl methyl carbonate, 2-methyl (2-ethoxy) ) Butyl methyl carbonate, 2-methyl (2-methoxy) pentyl methyl carbonate, 2-methyl (2-ethoxy) pentyl methyl carbonate, 1-phenyl (2-methoxy) propyl carbonate, 1-phenyl (2-methoxy) propyl carbonate, 1-phenyl (2 Ethoxy) propyl methyl carbonate, 1-phenyl (2-benzyloxy)
- (2-ethoxyethyl) methyl carbonate (2-ethoxyethyl) ethyl carbonate, 2-propoxyethyl ethyl carbonate, 2-butoxyethyl ethyl carbonate, (2-ethoxyethyl) phenyl carbonate, 2-ethoxyethyl- p-methylphenyl carbonate is particularly preferred.
- the compound represented by General formula (1) and General formula (2) can also be used individually or in combination of 2 or more types.
- the solid catalyst component (I) may contain an electron donating compound (hereinafter also referred to as component (B)) other than the component (A) represented by the general formula (1).
- Such components (B) include alcohols, phenols, acid halides, acid amides, nitriles, acid anhydrides, ether compounds, organic acid esters, silicic acid esters, ether groups and ester groups. And the like.
- Examples of the component (B) include alcohols such as ethanol, butyl alcohol, 2-ethylhexyl alcohol, 1,3-butanediol, phenol, cresol, 2,6-dibutylphenol, 1-naphthol, catechol, 3,5 -Phenols such as dibutylcatechol, acid halides such as benzoic acid chloride, phthalic acid dichloride, acetic acid chloride, nitriles such as butyramide, phenylamide, phthalic acid diamide, acetonitrile, cyanobenzene, 2-cyanobenzoic acid ester, Acid anhydrides such as phthalic anhydride, acetic anhydride, ethers such as dibutyl ether, diphenyl ether, 1,3-dimethoxy, 2,2-diisobutylpropane, 9,9-dimethoxyfluorene, benzoic acid ester, isobutyric acid ester, norborny
- Preferred components (B) include hydrocarbon-substituted malonic acid diesters such as malonic acid diesters such as dimethyl malonate and diethyl malonate, dimethyl diisobutylmalonate, diethyl diisobutylmalonate and diethyl benzylidenemalonate, diethyl maleate, and maleic acid diester.
- -Maleic acid diesters such as n-butyl, cycloalkane dicarboxylic acid diesters such as cyclohexane-1,2-dicarboxylic acid dimethyl, 1,1-norbornyl dicarboxylic acid diester.
- 2 or more types of such a component (B) can also be used together.
- the solid catalyst component (I) may contain polysiloxane (hereinafter also simply referred to as “component (F)”).
- component (F) polysiloxane
- Polysiloxane is a polymer having a siloxane bond (—Si—O— bond) in the main chain, but is also collectively referred to as silicone oil, and has a viscosity at 25 ° C. of 0.02 to 100 cm 2 / s (2 to 10,000 centistokes). ), More preferably 0.03 to 5 cm 2 / s (3 to 500 centistokes), a liquid or viscous chain, partially hydrogenated, cyclic or modified polysiloxane at room temperature.
- the disiloxanes are hexamethyldisiloxane, hexaethyldisiloxane, hexapropyldisiloxane, hexaphenyldisiloxane 1,3-divinyltetramethyldisiloxane, 1,3-dichlorotetramethyldisiloxane, 3-dibromotetramethyldisiloxane, chloromethylpentamethyldisiloxane, 1,3-bis (chloromethyl) tetramethyldisiloxane, and dimethylpolysiloxane and methylphenylpolysiloxane as polysiloxanes other than disiloxane are partially hydrogenated As hydrogenated polysiloxane, methylhydrogen polysiloxane having a hydrogenation rate of 10 to 80% is used.
- cyclic polysiloxane hexamethylcyclotrisiloxane, octamethylcyclotetrasiloxane, Tylcyclopentasiloxane, 2,4,6-trimethylcyclotrisiloxane, 2,4,6,8-tetramethylcyclotetrasiloxane, and modified polysiloxanes include higher fatty acid group-substituted dimethylsiloxane and epoxy group-substituted dimethylsiloxane. And polyoxyalkylene group-substituted dimethylsiloxane.
- decamethylcyclopentasiloxane and dimethylpolysiloxane are preferable, and decamethylcyclopentasiloxane is particularly preferable.
- the content of titanium, magnesium, halogen atom and component (A) in the solid catalyst component (I) is not particularly limited, but preferably 0.1 to 10% by weight of titanium, preferably 0.5 to 8%.
- the ratio of the component (D) content to the component (A) is 0.01 to 1 mol per
- the solid catalyst component (I) may further contain a reaction reagent containing a metal such as silicon, phosphorus or aluminum in addition to the above components.
- reaction agents include organosilicon compounds having Si—O—C bonds, organosilicon compounds having Si—N—C bonds, phosphate compounds having PO bonds, trialkylaluminum, dialkoxyaluminum chloride, Examples include organoaluminum compounds such as alkoxyaluminum dihalides and trialkoxyaluminums, and aluminum trihalides, preferably organosilicon compounds having a Si—O—C bond, organosilicon compounds having a Si—N—C bond, and organic It is an aluminum compound.
- the solid catalyst component (I) containing such a reaction reagent is preferable in that the polymerization activity and stereoregularity of the obtained solid catalyst component can be improved.
- organosilicon compound having a Si—O—C bond and the organosilicon compound having a Si—N—C bond examples include exemplified compounds and specific examples of organosilicon compounds represented by the following general formulas (3) and (4). Since the thing similar to a compound is mentioned, the description is abbreviate
- These reaction reagents may contain 1 type (s) or 2 or more types.
- R 13 represents a hydrogen atom or an alkyl group having 1 to 20 carbon atoms, a cycloalkyl group, a phenyl group, a vinyl group or a halogen atom, and may be the same or different
- u is 0 or 1 to 5
- an organic silicon compound having an unsaturated alkyl group represented by the following formula: t is an integer of 1 to 4.
- An unsaturated alkyl group is a vinyl group or an alkenyl group. Specifically, a vinyl group-containing alkylsilane, a vinyl group-containing alkoxysilane, a vinyl group-containing cycloalkylsilane, a vinyl group-containing phenylsilane, a vinyl group-containing halogen.
- Silane vinyl group-containing alkyl halogenated silane, alkenyl group-containing vinyl silane, alkenyl group-containing alkyl silane, alkenyl group-containing alkoxy silane, alkenyl group-containing cycloalkyl silane, alkenyl group-containing phenyl silane, alkenyl group-containing halogenated silane, alkenyl group Containing alkylhalogenated silanes.
- the vinyl group means CH 2 ⁇ CH— group
- the alkenyl group means CH 2 ⁇ CH— (CH 2 ) u — group.
- vinyltrialkylsilane, allyltrialkylsilane, divinyldialkylsilane, diallyldialkylsilane, trivinylalkylsilane and triallylalkylsilane are preferable, and allyldimethylvinylsilane, diallyldimethylsilane and triallylmethylsilane are particularly preferable.
- the organosilicon compound which has said unsaturated alkyl group may contain 1 type, or 2 or more types.
- the solid catalyst component (I) is composed of the following magnesium compound, titanium compound, and if necessary, a halogen compound other than the titanium compound, the compound (A) of the general formula (1), and the compound of the general formula (2) It is prepared by bringing (B) into contact with each other.
- Examples of the magnesium compound (C) include dihalogenated magnesium, dialkylmagnesium, halogenated alkylmagnesium, dialkoxymagnesium, diaryloxymagnesium, halogenated alkoxymagnesium, and fatty acid magnesium. 1 type or more chosen from is mentioned.
- magnesium dihalide, a mixture of magnesium dihalide and dialkoxymagnesium, and dialkoxymagnesium are preferable, and dialkoxymagnesium is particularly preferable.
- dialkoxymagnesium examples include dimethoxymagnesium, diethoxymagnesium, dipropoxymagnesium, dibutoxymagnesium, ethoxymethoxymagnesium, ethoxypropoxymagnesium, and butoxyethoxymagnesium. These dialkoxymagnesiums may be prepared by reacting metal magnesium with alcohol in the presence of halogen or a halogen-containing metal compound. One or more of the above dialkoxymagnesium can be used in combination.
- the dialkoxymagnesium is preferably in the form of granules or powder, and the shape may be indefinite or spherical.
- a polymer powder having a better particle shape and a narrow particle size distribution can be obtained at the time of polymerization, and the handling operability of the produced polymer powder during the polymerization operation is improved, and the produced polymer Problems such as blockage caused by fine powder contained in the powder are solved.
- the above spherical dialkoxymagnesium does not necessarily have a true spherical shape, and an elliptical shape or a potato shape can also be used.
- the particle shape is such that the ratio (l / w) of the major axis diameter l to the minor axis diameter w is 3 or less, preferably 1 to 2, more preferably 1 to 1.5. .
- the average particle diameter of the dialkoxymagnesium is 1 to 3 in terms of an average particle diameter D50 (50% in the cumulative particle size distribution) when measured using a laser light scattering diffraction particle size analyzer.
- the thickness is preferably 200 ⁇ m, more preferably 5 to 150 ⁇ m.
- the average particle size is preferably 1 to 100 ⁇ m, more preferably 5 to 50 ⁇ m, and even more preferably 10 to 40 ⁇ m. Further, as for the particle size, those having a small particle size distribution with less fine powder and coarse powder are desirable.
- the particle size of 5 ⁇ m or less is preferably 20% or less, more preferably 10% or less when measured using a laser light scattering diffraction particle size measuring instrument.
- particles having a particle size of 100 ⁇ m or more are preferably 10% or less, more preferably 5% or less.
- the particle size distribution is ln (D90 / D10) (where D90 is the cumulative particle size in the volume cumulative particle size distribution and 90% of the particle size, and D10 is the cumulative particle size in the volume cumulative particle size distribution of 10%). Is preferably 3 or less, more preferably 2 or less.
- JP-A-58-41832, JP-A-62-51633, JP-A-3-74341, JP-A-4-368391, and JP-A-8-73388 can be used to produce spherical dialkoxymagnesium as described above. It is exemplified in the publication.
- the component (C) either a solution-like magnesium compound or a magnesium compound suspension can be used.
- the component (C) is a solid, it is dissolved in a solvent having the solubilizing ability of the component (C) to form a solution-like magnesium compound, or a solvent having no solubilizing ability of the component (C). Suspend and use as a magnesium compound suspension.
- the component (C) is a liquid, it can be used as it is as a solution-like magnesium compound, or it can be used as a solution-like magnesium compound by dissolving it in a solvent capable of solubilizing the magnesium compound.
- Examples of the compound capable of solubilizing the solid component (C) include at least one compound selected from the group consisting of alcohols, ethers and esters. Specifically, methanol, ethanol, propanol, butanol, pentanol, hexanol, 2-ethylhexanol, octanol, dodecanol, octadecyl alcohol, oleyl alcohol, benzyl alcohol, phenylethyl alcohol, cumyl alcohol, isopropyl alcohol, isopropylbenzyl alcohol , Alcohols having 1 to 18 carbon atoms such as ethylene glycol, halogen-containing alcohols having 1 to 18 carbon atoms such as trichloromethanol, trichloroethanol, trichlorohexanol, methyl ether, ethyl ether, isopropyl ether, butyl ether, amyl ether , Tetrahydrofuran, e
- Examples include ethers having 2 to 20 elementary atoms, tetraethoxytitanium, tetra-n-propoxytitanium, tetraisopropoxytitanium, tetrabutoxytitanium, tetrahexoxytitanium, tetrabutoxyzirconium, tetraethoxyzirconium, and other metal acid esters.
- ethers having 2 to 20 elementary atoms
- tetraethoxytitanium tetra-n-propoxytitanium, tetraisopropoxytitanium, tetrabutoxytitanium, tetrahexoxytitanium, tetrabutoxyzirconium, tetraethoxyzirconium, and other metal acid esters.
- alcohols such as ethanol, propanol, butanol and 2-ethylhexanol are preferred, and 2-ethylhexano
- a saturated hydrocarbon solvent or an unsaturated hydrocarbon solvent that does not dissolve the magnesium compound is used as the medium that does not have the ability to solubilize the component (C).
- Saturated hydrocarbon solvents or unsaturated hydrocarbon solvents are high in safety and industrial versatility, and are specifically linear or branched with a boiling point of 50 to 200 ° C. such as hexane, heptane, decane, and methylheptane.
- cycloaliphatic hydrocarbon compounds such as cycloaliphatic hydrocarbon compounds, cyclohexane, ethylcyclohexane and decahydronaphthalene, and aromatic hydrocarbon compounds having a boiling point of 50 to 200 ° C. such as toluene, xylene and ethylbenzene.
- linear aliphatic hydrocarbon compounds having a boiling point of 50 to 200 ° C. such as hexane, heptane and decane
- aromatic hydrocarbon compounds having a boiling point of 50 to 200 ° C. such as toluene, xylene and ethylbenzene are preferably used. .
- these may be used independently or may be used in mixture of 2 or more types.
- titanium compound (D) examples include, for example, general formula (7); Ti (OR 14 ) j X 4-j (7) (R 14 is a hydrocarbon group having 1 to 10 carbon atoms, and when there are a plurality of OR 14 groups, the plurality of R 14 may be the same or different, X is a halogen group, In the case where a plurality of are present, each X may be the same or different, and j is 0 or an integer of 1 to 4.).
- the tetravalent titanium compound represented by the general formula (7) is one or more compounds selected from the group consisting of alkoxy titanium, titanium halides and alkoxy titanium halides.
- titanium tetrahalide such as titanium tetrafluoride, titanium tetrachloride, titanium tetrabromide, titanium tetraiodide, etc., methoxy titanium trichloride, ethoxy titanium trichloride, propoxy titanium trichloride, n-butoxy as alkoxy titanium halide
- Alkoxy titanium trihalides such as titanium trichloride, dimethoxy titanium dichloride, diethoxy titanium dichloride, dipropoxy titanium dichloride, di-n-butoxy titanium dichloride, dialkoxy titanium dihalide, trimethoxy titanium chloride, triethoxy titanium chloride, And trialkoxy titanium halides such as tripropoxy titanium chloride and tri-n-butoxy titanium chloride.
- halogen-containing titanium compounds are preferably used, and titanium tetrahalides such as titanium tetrachloride, titanium tetrabromide, and titanium tetraiodide are preferable, and titanium tetrachloride is particularly preferable. These titanium compounds may be used alone or in combination of two or more. Further, the tetravalent titanium compound represented by the general formula (7) may be used after diluted with a hydrocarbon compound or a halogenated hydrocarbon compound.
- a halogen compound other than the component (D) may be used as necessary.
- the halogen compound include tetravalent halogen-containing silicon compounds. More specifically, tetrachlorosilane (silicon tetrachloride), silane tetrahalides such as tetrabromosilane, methoxytrichlorosilane, ethoxytrichlorosilane, propoxytrichlorosilane, n-butoxytrichlorosilane, dimethoxydichlorosilane, diethoxydichlorosilane, Examples include alkoxy group-containing halogenated silanes such as dipropoxydichlorosilane, di-n-butoxydichlorosilane, trimethoxychlorosilane, triethoxychlorosilane, tripropoxychlorosilane, and tri-n-butoxychlorosilane.
- the component (A) used in the preparation of the solid catalyst component (I) is the same as the component (A) of the solid catalyst component (I), and the description thereof is omitted.
- the electron donating compound (B) other than the component (A) used as necessary in the preparation of the solid catalyst component (I) is the same as the electron donating compound (B) of the solid catalyst component (I). This is the same, and a description thereof is omitted.
- the component (F) used as necessary in the preparation of the solid catalyst component (I) is the same as the component (F) of the solid catalyst component (I), and the description thereof is omitted.
- suitable methods for preparing the solid catalyst component (I) include, for example, a method of co-grinding a solid magnesium compound having no reducing property, component (A) and titanium halide, and an adduct such as alcohol. Method of contacting magnesium halide compound having component, component (A), and titanium halide in the presence of inert hydrocarbon solvent, dialkoxymagnesium, component (A), and titanium halide in the presence of inert hydrocarbon solvent And a method in which a solid catalyst is deposited by bringing the reducing magnesium compound, the component (A) and titanium halide into contact with each other.
- an electron donating compound (B) other than the component (A) may be used in combination.
- Component (A) and component (B) may be used in the same reaction or sequentially. Furthermore, you may perform the said contact in coexistence of other reaction reagents, such as silicon, phosphorus, aluminum, and surfactant, for example.
- the solid catalyst component (I) can also be prepared by subjecting the solid component to a preliminary polymerization treatment with an organoaluminum compound, an organosilicon compound and an olefin.
- An organomagnesium compound such as dialkylmagnesium and an organoaluminum compound are brought into contact with alcohol in the presence of a hydrocarbon solvent to form a homogeneous solution, and a silicon compound such as silicon tetrachloride is brought into contact with this solution to form a solid.
- the solid product is contacted with titanium halide, component (A) and optionally component (B), and further contacted with titanium tetrachloride.
- a solid catalyst component (I) Magnesium chloride, tetraalkoxytitanium and aliphatic alcohol are contact-reacted in the presence of a hydrocarbon solvent to form a homogeneous solution, and after contacting the solution and titanium halide, the temperature is raised to precipitate a solid, A method in which the solid component is contacted with the component (A) and, if necessary, the component (B) simultaneously or sequentially and further reacted with titanium halide to obtain the solid catalyst component (I).
- a process using the component (B) may be added.
- titanium tetrachloride After adding titanium tetrachloride to the mixture, the temperature is raised to precipitate a solid product, and the solid product is contacted with component (A) and, if necessary, component (B) simultaneously or sequentially, and further titanium tetrachloride is contacted.
- a solid catalyst component (I) (7) Suspend dialkoxymagnesium in a hydrocarbon solvent, then contact with titanium tetrachloride, raise the temperature, and contact with component (A) and component (B) simultaneously or sequentially as necessary. To obtain a solid product, washing the solid product with a hydrocarbon solvent, and then contacting with titanium tetrachloride again in the presence of the hydrocarbon solvent to prepare the solid catalyst component (I) for olefin polymerization. At this time, the solid component can be heat-treated in the presence or absence of a hydrocarbon solvent. Moreover, you may add the process by a component (B) additionally.
- a solid product is obtained by contact reaction with titanium halide and component (A) and, if necessary, component (B).
- a method of obtaining a solid catalyst component (I) by washing with an inert organic solvent and then contacting and reacting with a titanium halide again in the presence of a hydrocarbon solvent. At this time, the solid component and the titanium halide can be contacted twice or more.
- Dialkoxymagnesium, calcium chloride and alkoxy group-containing silicon compound are co-pulverized and the obtained pulverized solid is suspended in a hydrocarbon solvent, and then the titanium halide, component (A) and, if necessary, A method for preparing a solid catalyst component (I) by contacting with component (B) and then further contacting with a titanium halide.
- a method of preparing a solid catalyst component (I) for polymerizing olefins by obtaining a solid product, washing the solid product with a hydrocarbon solvent, and then again contacting with a titanium halide in the presence of the hydrocarbon solvent. At this time, the solid component may be heat-treated in the presence or absence of a hydrocarbon solvent.
- a new titanium halide is added to the solid catalyst component (I) after washing. Then, the process of contacting with a hydrocarbon solvent at 20 to 100 ° C., raising the temperature and carrying out the reaction treatment (secondary reaction treatment) and then washing with a liquid inert organic solvent at room temperature is repeated 1 to 10 times. May be.
- any of the above-mentioned methods can be suitably used as a method for preparing component (I).
- (1), (3), (4), (5), (7) , (8) or (10) is preferred, and the methods (3), (4), (7), (8) and (10) are preferred in that a solid catalyst component having high stereoregularity can be obtained.
- the most preferred preparation method is dialkoxymagnesium, component (A) (or component (B)) selected from linear or branched aliphatic hydrocarbons, alicyclic hydrocarbons and aromatic hydrocarbons.
- the solid catalyst component (I) obtained by the above method is converted into an organosilicon compound having the Si—O—C bond, Si—N—
- One of the preferred embodiments of the present invention is to contact the organosilicon compound having a C bond, and if necessary, the organoaluminum compound, and if necessary, the organosilicon compound represented by the general formula (6). It is. These compounds are contacted in the presence of a hydrocarbon solvent. Moreover, after making each component contact, in order to remove an unnecessary component, it fully wash
- the temperature at which each component is brought into contact is ⁇ 10 ° C. to 100 ° C., preferably 0 ° C. to 90 ° C., particularly preferably 20 ° C. to 80 ° C.
- the contact time is 1 minute to 10 hours, preferably 10 minutes to 5 hours, particularly preferably 30 minutes to 2 hours.
- the amount ratio used when contacting each component is arbitrary as long as the effect is not adversely affected, and is not particularly limited.
- the organosilicon compound having a Si—O—C bond, the organosilicon compound having a Si—N—C bond, and the organosilicon compound component represented by the general formula (6) are contained in the solid catalyst component (I).
- the organoaluminum compound is a titanium atom in the solid catalyst component (I). It is used in the range of 0.5 to 50 mol, preferably 1 to 20 mol, particularly preferably 1.5 to 10 mol per mol.
- the obtained solid catalyst component (I) can be made into a powdery solid component by removing the solvent remaining until the weight ratio to the solid component is 1/3 or less, preferably 1/20 to 1/6. preferable.
- each component used in preparing the solid catalyst component (I) varies depending on the preparation method and cannot be defined unconditionally.
- a tetravalent titanium halogen compound (C) per mole of the magnesium compound (B) can be used.
- C tetravalent titanium halogen compound
- the total amount of component (A) and electron donating compound (B) (when component (I) contains electron donating compound (B)) is 0.01 to 10 mol, preferably 0.01 to 1 Mol, more preferably 0.02 to 0.6 mol
- the solvent is 0.001 to 500 mol, preferably 0.001 to 100 mol, more preferably 0.005 to 10 mol
- the polysiloxane (F ) Is 0.01-1 0 g, preferably 0.05 ⁇ 80 g, more preferably 1 ⁇ 50 g.
- the propylene-based block copolymerization catalyst used in the present invention comprises (I) a solid catalyst component, (II) an organoaluminum compound (hereinafter sometimes simply referred to as “component (G)”), and (III) external electron donation. (Hereinafter sometimes simply referred to as “component (H)”).
- component (I) contains the organosilicon compound having the Si—O—C bond, the organosilicon compound having the Si—N—C bond, or the organoaluminum compound (reaction reagent), or the reaction reagent.
- the use of the component (H) can be omitted. This is because even if the component (H) is not used, the solid catalyst component and the catalyst formed of organoaluminum exhibit performances excellent in polymerization activity and hydrogen responsiveness.
- the organoaluminum compound is not particularly limited as long as it is a compound represented by the general formula (2), but R 3 is preferably an ethyl group or an isobutyl group, and Q is a hydrogen atom, chlorine An atom, a bromine atom, an ethoxy group, and a phenoxy group are preferable, and p is preferably 2, 2.5 or 3, and particularly preferably 3.
- organoaluminum compounds include trialkylaluminum such as triethylaluminum, tri-iso-propylaluminum, tri-n-butylaluminum, tri-n-hexylaluminum, tri-iso-butylaluminum, and diethylaluminum.
- examples include chloride, halogenated alkylaluminum such as diethylaluminum bromide, diethylaluminum hydride, etc.
- alkylaluminum halide such as diethylaluminum chloride, or trialkylaluminum such as triethylaluminum, tri-n-butylaluminum and triisobutylaluminum.
- alkylaluminum halide such as diethylaluminum chloride
- trialkylaluminum such as triethylaluminum, tri-n-butylaluminum and triisobutylaluminum.
- These aluminum compounds can
- Examples of the (III) external electron donating compound used in forming the copolymerization catalyst used in the present invention include organic compounds containing oxygen atoms or nitrogen atoms, such as alcohols, phenols, ethers. Esters, ketones, acid halides, aldehydes, amines, amides, nitriles, isocyanates, organosilicon compounds, especially organosilicon compounds having Si—O—C bonds or Si—N—C bonds And aminosilane compounds having the same.
- esters such as ethyl benzoate, ethyl p-methoxybenzoate, ethyl p-ethoxybenzoate, methyl p-toluate, ethyl p-toluate, methyl anisate, ethyl anisate, etc.
- 1,3-diethers organosilicon compounds containing Si—O—C bonds, aminosilane compounds containing Si—N—C bonds are preferred, organosilicon compounds having Si—O—C bonds, Si—N— Particularly preferred are aminosilane compounds having a C bond and 1,3-diethers having a substituent at the 2-position.
- the organosilicon compound having a Si—O—C bond is represented by the following general formula (3): R 4 Si (OR 5 ) 4-q (3) Wherein R 4 is an alkyl group having 1 to 12 carbon atoms, a vinyl group, an alkenyl group having 3 to 12 carbon atoms, a cycloalkyl group having 3 to 12 carbon atoms or a cycloalkenyl group, and an aromatic group having 6 to 15 carbon atoms.
- R 5 represents a hydrocarbon group or an aromatic hydrocarbon group having a substituent, which may be the same or different, and R 5 represents an alkyl group having 1 to 4 carbon atoms, a vinyl group, an alkenyl group having 3 to 12 carbon atoms, a carbon number A cycloalkyl group having 3 to 6 carbon atoms, an aromatic hydrocarbon group having 6 to 12 carbon atoms, or an aromatic hydrocarbon group having 7 to 12 carbon atoms having a substituent, which may be the same or different, and q is 0 ⁇ q ⁇ 3)).
- the aminosilane compound having a Si—N—C bond includes the general formula (4); (R 6 R 7 N) s SiR 8 4-s (4) (Wherein R 6 and R 7 are a hydrogen atom, an alkyl group having 1 to 20 carbon atoms, a vinyl group, an alkenyl group having 3 to 20 carbon atoms, a cycloalkyl group having 3 to 20 carbon atoms, a cycloalkenyl group, or a carbon number) R 6 and R 7 may be the same or different and may be bonded to each other to form a ring, and R 8 is an alkyl group having 1 to 20 carbon atoms, a vinyl group, An alkenyl group having 3 to 12 carbon atoms, an alkoxy group having 1 to 20 carbon atoms, a vinyloxy group, an alkenyloxy group having 3 to 20 carbon atoms, a cycloalkyl group or cycloalkyloxy group having 3 to 20 carbon
- organosilicon compound represented by the general formula (3) or (4) examples include phenylalkoxysilane, alkylalkoxysilane, phenylalkylalkoxysilane, cycloalkylalkoxysilane, alkyl (cycloalkyl) alkoxysilane, (alkylamino) ) Alkoxysilane, alkyl (alkylamino) alkoxysilane, cycloalkyl (alkylamino) alkoxysilane, tetraalkoxysilane, tetrakis (alkylamino) silane, alkyltris (alkylamino) silane, dialkylbis (alkylamino) silane, trialkyl And (alkylamino) silane.
- 1,3-diethers having a substituent at the 2-position include the following general formula (5): R 9 OCH 2 CR 10 R 11 CH 2 OR 12 (5) Wherein R 10 and R 11 are a hydrogen atom, a halogen atom, an alkyl group having 1 to 12 carbon atoms, a vinyl group, an alkenyl group having 3 to 12 carbon atoms, a cycloalkyl group having 3 to 12 carbon atoms or a cycloalkenyl group.
- 2-isopropyl-2- Isobutyl-1,3-dimethoxypropane, 2-isopropyl-2-isopentyl-1,3-dimethoxypropane, 9,9-bis (methoxymethyl) fluorene and the like are preferably used, and at least one or two of these compounds are used.
- the above can be used.
- propylene and ⁇ -olefin copolymerization method In the present invention, propylene and ⁇ -olefin are copolymerized in the presence of the copolymerization catalyst to produce a propylene-based block copolymer.
- the ⁇ -olefin is at least one olefin selected from ⁇ -olefins having 2 to 20 carbon atoms (excluding propylene having 3 carbon atoms), such as ethylene, 1-butene, 1-pentene, 4- Examples thereof include methyl-1-pentene and vinylcyclohexane.
- ⁇ -olefins can be used alone or in combination of two or more. Among them, ethylene and 1-butene are preferably used. Particularly preferred is ethylene.
- the copolymerization in the present invention includes a slurry polymerization method using a solvent of an inert hydrocarbon compound such as cyclohexane and heptane, a bulk polymerization method using a solvent such as liquefied propylene, and a gas phase polymerization substantially using no solvent. Lawful.
- a block copolymer can be obtained by repeating these steps in multiple stages.
- a preferable copolymerization method is a combination of a bulk polymerization method and a gas phase polymerization method, or a multistage gas phase polymerization method.
- the copolymerization of the present invention is carried out by polymerizing propylene alone in the preceding stage or copolymerizing propylene and a small amount of ⁇ -olefin, particularly ethylene, and then copolymerizing propylene and ⁇ -olefin, particularly ethylene, or propylene in the latter stage. It is preferable to carry out terpolymerization of ethylene, ethylene and 1-butene. In addition, the process can also be implemented in multiple times in both the former stage and the latter stage.
- polymerization is carried out by adjusting the polymerization temperature and time at a ratio of 20 to 90% by weight of the total propylene block copolymer in the former stage, and then in the latter stage, propylene and ethylene or other
- An ⁇ -olefin is introduced and a rubber part such as ethylene-propylene rubber (EPR) or ethylene-propylene-1-butene terpolymer is polymerized so that the ratio of the rubber part is 10 to 80% by weight. It is preferable.
- EPR ethylene-propylene rubber
- terpolymer ethylene-propylene-1-butene terpolymer
- Both the polymerization temperature in the former stage and the latter stage are 200 ° C. or less, preferably 100 ° C. or less, and the polymerization pressure is 10 MPa or less, preferably 5 MPa or less.
- the residence time is usually 1 minute to 5 hours.
- the copolymerization of the present invention may be either a continuous polymerization method or a batch polymerization method.
- the polymerization reaction may be performed in one stage or multiple stages in both the first and second stages. When the first and second stages are performed in multiple stages, the polymerization reaction can be performed under the same conditions or different conditions.
- the latter stage is preferably a gas phase polymerization reaction in that elution of EPR from the PP particles can be suppressed.
- the ratio of the amount of each catalyst component used is arbitrary as long as the effects of the present invention are exhibited.
- the organoaluminum compound (G) is 1 per 1 mole of titanium atoms in the solid catalyst component (I). It is used in the range of -2000 mol, preferably 50-1000 mol.
- the external electron donating compound (H) is used in an amount of 0.002 to 10 mol, preferably 0.01 to 2 mol, particularly preferably 0.01 to 0.5 mol, per mol of the component (G). .
- the order of contacting the components is arbitrary, but it is desirable to first introduce the organoaluminum compound (G) into the polymerization system and then contact the component (I).
- an olefin when copolymerized using a catalyst containing a solid catalyst component, an organoaluminum compound, and an external electron donating compound (also referred to as main polymerization), catalytic activity, stereoregularity, and formation are generated.
- main polymerization an organoaluminum compound, and an external electron donating compound
- the same olefins as in the main polymerization or monomers such as styrene can be used.
- the order of contacting the respective components and monomers is arbitrary, but preferably the component (G) is first charged into the prepolymerization system set to an inert gas atmosphere or an olefin gas atmosphere, and then the solid After contacting the catalyst component (I), an olefin such as propylene, or a mixture of propylene and one or more other olefins is contacted.
- the component (G) is first charged into the prepolymerization system set to an inert gas atmosphere or an olefin gas atmosphere, and then the solid After contacting the catalyst component (I), an olefin such as propylene, or a mixture of propylene and one or more other olefins is contacted.
- the component (G) is first charged into the prepolymerization system set in an inert gas atmosphere or an olefin gas atmosphere, and then (H) is contacted. Further, after contacting the solid catalyst component (I), a method of contacting an olefin such as propylene or a mixture of propylene and one or more other olefins is desirable.
- an olefin such as propylene or a mixture of propylene and one or more other olefins is desirable.
- the production method of the present invention since the above catalyst is used, a large amount of rubber can be added even under the same conditions, and the block copolymer can be applied to a wide range of products.
- the polymerization of the rubber part is high, and the properties of the rubber part can be controlled by multistage polymerization of the rubber part.
- a block copolymer is a polymer containing a segment in which two or more types of monomer compositions continuously change, and includes monomer type, comonomer type, comonomer composition, comonomer content, comonomer arrangement, and stereoregularity.
- the propylene-based block copolymer obtained by the method of the present invention has a different monomer composition although the polymer chain (segment) having different primary structure of the polymer is connected in two or more types in one molecular chain.
- These polymers are produced by multi-stage polymerization, and some of them are linked as polymer chains, but the main part is composed of two or more polymers obtained with different monomer compositions.
- the polymer particles are mixed and exist.
- the propylene block copolymer obtained by the method of the present invention is crystalline polypropylene, or a crystalline polypropylene random copolymer containing a small amount of crystalline polypropylene and an ⁇ -olefin such as ethylene (crystalline PP, homo part).
- crystalline PP crystalline polypropylene
- an ⁇ -olefin such as ethylene
- the balance between rigidity and impact resistance varies depending on the ratio of crystalline PP and rubber part, but the propylene block copolymer obtained by the method of the present invention has a polymerization activity of rubber part obtained by subsequent polymerization (
- the ratio of the rubber part in the copolymer is high because the block ratio is high, and the amount of rubber part and the ethylene content in the crystal part are commensurate with the amount of ⁇ -olefin such as ethylene contained in the random copolymer. Relatively high rigidity is exhibited, and high impact strength is exhibited when matching the same rubber part polymer.
- the magnesium atom content in the solid catalyst component is determined by weighing the solid catalyst component from which the solvent component has been completely removed by heating under reduced pressure in advance, dissolving in hydrochloric acid solution, adding indicator methyl orange and saturated ammonium chloride solution, and adding ammonia. Heated after neutralization with water, filtered to a constant volume after cooling to remove the precipitate (Ti hydroxide), and a certain amount of the obtained filtrate was taken, and after heating, mixed buffer and EBT indicator And was measured by the EDTA titration method of titrating with an EDTA solution.
- titanium atom content in the solid catalyst component The titanium atom content in the solid catalyst component was measured according to the method described in JIS 8311-1997 “Method for quantifying titanium in titanium ore” (redox titration).
- the halogen atom content in the solid catalyst component is a constant volume after weighing the solid catalyst component from which the solvent component has been completely removed by heating under reduced pressure and treating it with a mixed solution of sulfuric acid and pure water to obtain an aqueous solution.
- a silver nitrate titration method in which halogen atoms were titrated with a silver nitrate standard solution using an automatic titrator (COM-1500, manufactured by Hiranuma Sangyo Co., Ltd.).
- the contents of the first internal electron donor to the third internal electron donating compound contained in the solid catalyst component are as follows using gas chromatography (manufactured by Shimadzu Corporation, GC-14B). It was calculated by measuring. Further, the number of moles of each component (each internal electron donating compound) was determined from a measurement result of gas chromatography using a calibration curve measured in advance at a known concentration.
- the 1H-NMR chemical shift values were 1.14 (t, 3H), 1.23 (t, 3H), 3.46 (q, 2H), 3.56 to Since it was 3.62 (m, 2H), 4.12 (q, 2H), 4.18 to 4.23 (m, 2H), the obtained product was 2-ethoxyethyl-1-ethyl. It was confirmed to be carbonate. As a result of measurement by GC, the purity of the obtained 2-ethoxyethyl-1-ethyl carbonate was 98.0%.
- B1 ethylene-propylene copolymerization catalyst
- the monomer was purged while lowering the temperature of the reactor to room temperature, and then the weight of the entire autoclave was weighed to determine the amount of polymerization in the previous stage from the difference from the weight weighed in advance before the start of polymerization. .
- the monomer supply line After sampling a part of the polymer for MFR measurement under nitrogen, connect the monomer supply line again, so that the molar ratio of ethylene / propylene / hydrogen is 1.0 / 1.0 / 0.043, respectively.
- the temperature was raised to 70 ° C., and ethylene / propylene / hydrogen was introduced at a ratio of 2/2 / 0.086 of liter / minute, respectively.
- a propylene-based block copolymer was obtained.
- propylene-based block copolymer activity (ICP (impact copolymer) activity) (g-ICP / (g-cat)
- polymerization ratio of the copolymer part block (Efficiency) (wt%) was measured to evaluate the polymerization activity sustainability, and the MFR of the homo-stage polymer, the MFR of the entire ICP, and the EPR content indicating the rubber amount of the resulting propylene block copolymer ( wt%), ethylene content in EPR (wt%), ethylene content in xylene insolubles (wt%), flexural modulus (FM) (MPa), and Izod impact strength (KJ / m 2 ).
- ICP impact copolymer activity
- g-ICP / (g-cat) polymerization ratio of the copolymer part
- block Efficiency
- the propylene block copolymerization activity per 1 g of the solid catalyst component was determined by the following formula.
- Propylene block copolymerization activity (g-ICP / g-catalyst) (I (g) ⁇ F (g) + J (g)) / [ ⁇ mass of solid catalyst component in olefin polymerization catalyst (g) ⁇ ((G (g) ⁇ F (g) ⁇ J (g )) ⁇ / (G (g) -F (g)))]
- I is autoclave mass (g) after completion of copolymerization reaction
- F autoclave mass (g)
- G autoclave mass (g) after removal of unreacted monomer after completion of homo-PP polymerization
- J homopolymer. This is the amount of polymer (g) extracted after polymerization.
- Block ratio (mass%) ⁇ (I (g) ⁇ G (g) + J (g)) / (I (g) ⁇ F (g)) ⁇ ⁇ 100
- I autoclave mass (g) after completion of copolymerization reaction
- G autoclave mass (g) after removal of unreacted monomers after completion of homo PP polymerization
- J polymer amount (g) extracted after homopolymerization.
- F autoclave mass (g).
- the ethylene content in EPR was obtained by sampling a small amount of the EPR part (xylene soluble content) obtained by xylene extraction in the above EPR content (xylene soluble content amount in ICP polymer) measurement operation, and forming it into a film by hot pressing. After molding, the absorbance was measured using a Fourier transform infrared spectrometer (FT-IR) (manufactured by Thermonicolete, Avatar) and the thickness of the film, and calculation was performed based on a calibration curve prepared from a plurality of samples with known contents. Measurement wavelength: 720 cm ⁇ 1 and 1150 cm ⁇ 1 Film thickness: 0.1-0.2mm
- FT-IR Fourier transform infrared spectrometer
- melt flowability (MFR)> The melt flow rate (MFR) (g / 10 minutes) indicating the melt flowability of homopolypropylene and ICP polymer was measured according to ASTM D 1238 and JIS K 7210.
- ⁇ Flexural modulus (FM) of polymer> a test piece for measuring physical properties was molded using the above polymer, and after conditioning for 144 hours or more in a thermostatic chamber adjusted to 23 ° C., liquid or powder exuded on the surface. What was not recognized was used as a test piece, and the bending elastic modulus (FM) (MPa) of the test piece was measured.
- the test piece was molded with respect to the obtained ethylene-propylene copolymer by 0.10% by weight of IRGANOX 1010 (manufactured by BASF), 0.10% by weight of IRGAFOS 168 (manufactured by BASF), and calcium stearate 0 0.08% by weight and kneaded and granulated with a single screw extruder to obtain a pellet-shaped ethylene-propylene copolymer, and then the pellet-shaped copolymer was molded at a mold temperature of 60 ° C. and a cylinder temperature. The product was introduced into an injection molding machine maintained at 230 ° C. and carried out by injection molding.
- IRGANOX 1010 manufactured by BASF
- IRGAFOS 168 manufactured by BASF
- calcium stearate 0.08% by weight are blended with the obtained ethylene-propylene copolymer.
- the mixture was kneaded and granulated with a single screw extruder to obtain a pellet-like ethylene-propylene copolymer.
- the pellet-shaped copolymer was introduced into an injection molding machine maintained at a mold temperature of 60 ° C. and a cylinder temperature of 230 ° C., and a test piece for measuring physical properties was injection molded by injection molding.
- test piece shape ISO 180 / 4A, thickness 3.2 mm, width 12.7 mm, length 63.5 mm
- Notch shape Type A notch (notch radius 0.25 mm), formed with a notched die.
- Example 2 ⁇ Formation of polymerization catalyst (B2) and production of propylene-based block copolymer> Formation of a polymerization catalyst (B2) and evaluation of polymerization were conducted in the same manner as in Example 1 except that 0.24 mmol of diisopropyldimethoxysilane (DIPDMS) was used instead of 0.24 mmol of dicyclopentyldimethoxysilane (DCPDMS). It was. The polymerization results are shown in Table 1.
- DIPDMS diisopropyldimethoxysilane
- DCPDMS dicyclopentyldimethoxysilane
- Example 3 Synthesis of Solid Catalyst Component (A3)> Instead of 2-ethoxyethyl-1-phenyl carbonate, the solid catalyst component (A3) was prepared in the same manner as in Example 1 except that the same mole of 2-ethoxyethyl-1-ethyl carbonate obtained in Production Example 2 was used. Prepared. The titanium content in the obtained solid catalyst component was 1.6% by weight.
- Example 4 ⁇ Preparation of solid catalyst component (A4)> 120 ml of purified n-heptane was introduced into a 500 ml round-bottom flask that had been sufficiently purged with nitrogen. Furthermore, 15 g of anhydrous magnesium chloride and 106 ml of tetrabutoxy titanium were added and reacted at 90 ° C. for 1.5 hours to obtain a uniform solution. The homogeneous lysate was then cooled to 40 ° C. 24 ml of methyl hydrogen polysiloxane (20 centistokes) was added while maintaining the temperature at 40 ° C., and a precipitation reaction was performed for 5 hours. The precipitated solid product was thoroughly washed with purified n-heptane.
- Solid catalyst component (a2) was prepared in the same manner as in Example 1, except that the same mole of 2-isopropyl-2-isopentyl-1,3-dimethoxypropane was used in place of 2-ethoxyethyl-1-phenyl carbonate.
- the titanium content in the obtained solid catalyst component was 2.5% by weight.
- Example 5 ⁇ Preparation of solid catalyst component (A5)>
- the solid catalyst component (A5) was obtained in the same manner as in Example 1 except that the same mole of 2-ethoxyethyl-1-methyl carbonate obtained in Production Example 3 was used instead of 2-ethoxyethyl-1-phenyl carbonate. Was prepared.
- the titanium content in the obtained solid catalyst component was 1.7% by weight.
- a polymerization catalyst (B5) was formed and polymerized in the same manner as in Example 1 except that the solid catalyst component (A5) was used instead of the solid catalyst component (A1).
- the polymerization results are shown in Table 1.
- Example 6 ⁇ Preparation of solid catalyst component (A6)>
- the solid catalyst component (A6) was obtained in the same manner as in Example 1 except that the same mole of 2-methoxyethyl-1-methyl carbonate obtained in Production Example 4 was used instead of 2-ethoxyethyl-1-phenyl carbonate. Was prepared.
- the titanium content in the obtained solid catalyst component was 1.5% by weight.
- Example 7 ⁇ Preparation of solid catalyst component (A7)> A solid was obtained in the same manner as in Example 1, except that the same mole of 2-ethoxyethyl-1- (p-methylphenyl) carbonate obtained in Production Example 5 was used instead of 2-ethoxyethyl-1-phenyl carbonate. A catalyst component (A7) was prepared. The titanium content in the obtained solid catalyst component was 2.7% by weight.
- Example 8 ⁇ Preparation of solid catalyst component (A8)> A flask with an internal volume of 200 ml, equipped with a stirrer and sufficiently substituted with nitrogen gas, was charged with 5.6 g of the solid catalyst component obtained in Example 1 and 70 ml of heptane to form a suspension. Warmed to. While stirring, 6 mmol of divinyldimethylsilane, 18 mmol of triethylaluminum and 6 mmol of dicyclopentyldimethoxysilane were sequentially added, 15 ml of heptane was introduced, and the reaction was performed at 30 ° C. for 2 hours.
- a polymerization catalyst (B8) was prepared in the same manner as in Example 1 except that the solid catalyst component (A8) was used instead of the solid catalyst component (A1) and the addition of 0.24 mmol of dicyclopentyldimethoxysilane (DCPDMS) was omitted.
- DCPDMS dicyclopentyldimethoxysilane
- Example 9 ⁇ Synthesis of solid catalyst component (A9)> A flask having an internal volume of 500 ml, equipped with a stirrer and sufficiently substituted with nitrogen gas, was charged with 10 g (87.4 mmol) of diethoxymagnesium, 55 ml of toluene, 30 ml of titanium tetrachloride, and 15.3 mmol of diethyl diisobutylmalonate (3. 8g) was added and the temperature was raised to 100 ° C. Thereafter, the reaction was carried out for 90 minutes while maintaining a temperature of 100 ° C. After completion of the reaction, the reaction product was washed 4 times with 75 ml of 100 ° C. toluene.
- a polymerization catalyst (B9) was formed and evaluated for polymerization in the same manner as in Example 1, except that the solid catalyst component (A9) was used instead of the solid catalyst component (A1).
- the polymerization results are shown in Table 1.
- reaction product was washed 4 times with 75 ml of 100 ° C. toluene.
- 100 ml of a 10% by volume titanium tetrachloride toluene solution was newly added, the temperature was raised to 100 ° C., the mixture was stirred for 15 minutes to react, and after the reaction, the product was washed once with 100 ° C. toluene. This operation was further performed twice, and then washed 6 times with 75 ml of n-heptane at 40 ° C. to obtain a solid catalyst component (A10).
- the solid solution of the solid catalyst component (A10) was separated, and the titanium content, diethyl benzylidene malonate content and carbonic acid (2-ethoxyethyl) (p-methylphenyl) content in the solid content were measured. They were 2% by weight, 9.2% by weight, and 3.1% by weight.
- a polymerization catalyst (B10) was formed and evaluated for polymerization in the same manner as in Example 1 except that the solid catalyst component (A10) was used instead of the solid catalyst component (A1).
- the polymerization results are shown in Table 1.
- Example 11 ⁇ Formation of polymerization catalyst (B11) and production of propylene-based block copolymer> Formation of a polymerization catalyst (B11) and evaluation of polymerization were carried out in the same manner as in Example 10 except that 0.24 mmol of diisopropyldimethoxysilane (DIPDMS) was used instead of 0.24 mmol of dicyclopentyldimethoxysilane (DCPDMS). It was. The polymerization results are shown in Table 1.
- DIPDMS diisopropyldimethoxysilane
- DCPDMS dicyclopentyldimethoxysilane
- Example 12 ⁇ Formation of polymerization catalyst> The formation and evaluation of the polymerization catalyst (B12) were conducted in the same manner as in Example 1 except that 0.24 mmol of diethylaminotriethoxysilane (DEATES) was used instead of 0.24 mmol of dicyclopentyldimethoxysilane (DCPDMS). I did it. The polymerization results are shown in Table 1.
- DEATES diethylaminotriethoxysilane
- DCPDMS dicyclopentyldimethoxysilane
- Comparative Example 3 In place of the solid catalyst component (A1), the solid catalyst component (a1) produced in Comparative Example 1 was used, and in place of 0.24 mmol of dicyclopentyldimethoxysilane (DCPDMS), diethylaminotriethoxysilane (DEATES) 0. The formation of the polymerization catalyst (b3) and the evaluation of the polymerization were performed in the same manner as in Example 1 except that 24 mmol was used. The polymerization results are shown in Table 1.
- Example 13 ⁇ Production of propylene block copolymer> After carrying out the block copolymerization shown in Example 3, the monomer gas was purged, the total weight was weighed, and the amount of the second stage ethylene propylene copolymer was confirmed. Next, the monomer line was connected again, 10 g of 1-butene was added, and then ethylene / propylene / hydrogen were mixed in the autoclave equipped with a stirrer so that the molar ratio was 2.0 / 1.0 / 0.086, respectively.
- Example 14 ⁇ Production of propylene block copolymer> Similar to Example 1 except that the polymerization catalyst (B3) used in Example 3 was used instead of the polymerization catalyst (B1) and that the subsequent polymerization time was changed to 2 hours instead of 1 hour. To obtain a propylene-based block copolymer. The results are shown in Table 1.
- Example 15 ⁇ Production of propylene block copolymer>
- the polymerization catalyst (B1) the polymerization catalyst (B3) used in Example 3 was used. Further, instead of the ICP polymerization after completion of the homostage polymerization in Example 1, the following ICP polymerization was performed. The reaction was carried out in the same manner as in Example 1 to obtain a propylene-based block copolymer. The results are shown in Table 1.
- the olefin polymerization catalysts prepared using the solid catalyst components obtained in Examples 1 to 15 have high copolymerization activity in the latter stage when multistage polymerization is performed, and propylene- Since a large amount of ethylene is introduced into the ethylene block copolymer, it is excellent in the polymerization sustainability of olefins during copolymerization.
- the resulting copolymer has a good block ratio and ethylene is efficiently introduced into the rubber part, providing a good balance between rigidity and impact strength. It turns out that it is.
- the solid catalyst component that does not use the compound represented by component (A) as the internal electron donating compound is inferior in the polymerization activity sustainability of olefins.
- the total yield of the ethylene block copolymer is increased, but the incorporation rate of the latter-stage ethylene into the random copolymer is decreased. Therefore, the subsequent copolymerization activity (block ratio) and the rubber part (EPR) content in the copolymer obtained are low.
- the amount of ethylene in the rubber part (EPR) with respect to the total amount of ethylene in the copolymer decreases, and the balance between rigidity and impact strength is poor.
- a novel solid catalyst component for polymerizing olefins by using a novel solid catalyst component for polymerizing olefins, it becomes possible to perform polymerization with excellent production characteristics of copolymer rubber, and as a result, a propylene block having an excellent balance of rigidity and impact strength.
- a method for producing a propylene-based block copolymer capable of providing a copolymer can be provided.
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Abstract
Description
(式中、R1およびR2は、炭素数1~20の直鎖状アルキル基、炭素数3~20の分岐アルキル基、ビニル基、炭素数3~20の直鎖状アルケニル基または分岐アルケニル基、炭素数1~20の直鎖状ハロゲン置換アルキル基、炭素数3~20の分岐ハロゲン置換アルキル基、炭素数2~20の直鎖状ハロゲン置換アルケニル基、炭素数3~20の分岐ハロゲン置換アルケニル基、炭素数3~20のシクロアルキル基、炭素数3~20のシクロアルケニル基、炭素数3~20のハロゲン置換シクロアルキル基、炭素数3~20のハロゲン置換シクロアルケニル基、炭素数6~24の芳香族炭化水素基、炭素数6~24のハロゲン置換芳香族炭化水素基、結合末端が炭素原子である炭素数2~24の窒素原子含有炭化水素基、結合末端が炭素原子である炭素数2~24の酸素原子含有炭化水素基、結合末端が炭素原子である炭素数2~24のリン含有炭化水素基、または炭素数1~24のケイ素含有炭化水素基を示し、同一でも異なっていてもよく、但し、該炭素数2~24の窒素原子含有炭化水素基は、結合末端がC=N基であるもの、該炭素数2~24の酸素原子含有炭化水素基は、結合末端がカルボニル基であるもの、該炭素数2~24のリン含有炭化水素基は、結合末端がC=P基であるものをそれぞれ除く。Zは、炭素原子又は炭素鎖を介して結合する結合性基を示す。)で表される化合物を含有する固体触媒成分、
(II)下記一般式(2);
R3 pAlQ3-p (2)
(式中、R3は炭素数1~6のヒドロカルビル基を示し、複数個ある場合は、同一でも異なってもよく、Qは水素原子、炭素数1~6のヒドロカルビルオキシ基、あるいはハロゲン原子を示し、pは0<p≦3の実数である。)で表わされる有機アルミニウム化合物、および
(III)外部電子供与性化合物、から形成される共重合用触媒の存在下に、プロピレンとα-オレフィンを共重合することを特徴とするプロピレン系ブロック共重合体の製造方法を提供するものである。
本発明のプロピレン系ブロック共重合体の製造方法で使用する共重合用固体触媒成分(以下、単に「成分(I)」と言うことがある。)は、マグネシウム、チタン、ハロゲンおよび、電子供与性化合物として上記一般式(1)で表される電子供与性化合物(以下、単に「成分(A)」ということがある。)を必須成分として含有する。
〔CH2=CH-(CH2)u〕tSiR13 4-t (6)
(式中、R13は水素原子または炭素数1~20のアルキル基、シクロアルキル基、フェニル基、ビニル基、ハロゲン原子を示し、同一または異なっていてもよく、uは0または1~5の整数であり、tは1~4の整数である。)で表わされる不飽和アルキル基を有する有機ケイ素化合物を含有するものであってもよい。これにより、得られる固体触媒成分のさらなる重合活性や水素応答性を向上できる。
固体触媒成分(I)は、下記のようなマグネシウム化合物、チタン化合物、必要に応じて前記チタン化合物以外のハロゲン化合物および前記一般式(1)の化合物(A)および前記一般式(2)の化合物(B)を相互に接触させることで調製される。
(R14は、炭素数1~10の炭化水素基であり、OR14基が複数存在する場合、複数のR14は同一であっても異なっていてもよく、Xはハロゲン基であり、Xが複数存在する場合、各Xは同一であっても異なっていてもよく、jは0または1~4の整数である。)で表わされる4価のチタン化合物を挙げることができる。
(2)ハロゲン化マグネシウム及びアルコールを反応させて均一溶液とした後、該均一溶液にカルボン酸無水物を接触させ、次いでこの溶液に、ハロゲン化チタン、成分(A)および必要に応じて成分(B)を接触反応させて固体物を得、該固体物に更にハロゲン化チタンを接触させて固体触媒成分(I)を調製する方法。
(3)金属マグネシウム、ブチルクロライド及びジアルキルエーテルを反応させることによって有機マグネシウム化合物を合成し、該有機マグネシウム化合物にアルコキシチタンを接触反応させて固体生成物を得、該固体生成物に成分(A)、必要に応じて成分(B)、及びハロゲン化チタンを同時にあるいは逐次的に接触反応させてオレフィン類重合用固体触媒成分(I)を調製する方法。なおこの際、該固体成分に対し、有機アルミニウム化合物、有機ケイ素化合物及びオレフィンで予備的な重合処理を行ない、固体触媒成分(I)を調製することもできる。
(4)ジアルキルマグネシウム等の有機マグネシウム化合物と、有機アルミニウム化合物を、炭化水素溶媒の存在下、アルコールと接触反応させて均一溶液とし、この溶液に四塩化ケイ素等のケイ素化合物を接触させて固体生成物を得、次いで芳香族炭化水素溶媒の存在下で該固体生成物に、ハロゲン化チタン、成分(A)および必要に応じて成分(B)を接触反応させた後、更に四塩化チタンを接触させて固体触媒成分(I)を得る方法。
(5)塩化マグネシウム、テトラアルコキシチタン及び脂肪族アルコールを、炭化水素溶媒の存在下で接触反応させて均一溶液とし、その溶液とハロゲン化チタンを接触した後昇温して固体物を析出させ、該固体物に成分(A)、および必要に応じて成分(B)を同時にあるいは逐次的に接触させ、更にハロゲン化チタンと反応させて固体触媒成分(I)を得る方法。さらに追加で成分(B)による処理を加えても良い。
(6)金属マグネシウム粉末、アルキルモノハロゲン化合物及びヨウ素を接触反応させ、その後テトラアルコキシチタン、酸ハロゲン化物、及び脂肪族アルコールを、炭化水素溶媒の存在下で接触反応させて均一溶液とし、その溶液に四塩化チタンを加えた後昇温し、固体生成物を析出させ、該固体生成物に成分(A)および必要に応じて成分(B)を同時にあるいは逐次的に接触させ、更に四塩化チタンと反応させて固体触媒成分(I)を調製する方法。
(7)ジアルコキシマグネシウムを炭化水素溶媒に懸濁させた後、四塩化チタンと接触させた後に昇温し、成分(A)および必要に応じて成分(B)と同時にあるいは逐次的に接触させて固体生成物を得、該固体生成物を炭化水素溶媒で洗浄した後、炭化水素溶媒の存在下、再度四塩化チタンと接触させてオレフィン類重合用固体触媒成分(I)を調製する方法。なおこの際、該固体成分を、炭化水素溶媒の存在下又は不存在下で加熱処理することもできる。また、追加で成分(B)による処理を加えても良い。
(8)ジアルコキシマグネシウムを炭化水素溶媒に懸濁させた後、ハロゲン化チタン及び成分(A)および必要に応じて成分(B)と接触反応させて固体生成物を得、該固体生成物を不活性有機溶媒で洗浄した後、炭化水素溶媒の存在下、再度ハロゲン化チタンと接触・反応させて固体触媒成分(I)を得る方法。なおこの際、該固体成分とハロゲン化チタンとを2回以上接触させることもできる。
(9)ジアルコキシマグネシウム、塩化カルシウム及びアルコキシ基含有ケイ素化合物を共粉砕し、得られた粉砕固体物を炭化水素溶媒に懸濁させた後、ハロゲン化チタン、成分(A)および必要に応じて成分(B)と接触反応させ、次いで更にハロゲン化チタンを接触させることにより固体触媒成分(I)を調製する方法。
(10)ジアルコキシマグネシウム及び成分(A)、必要に応じて成分(B)を炭化水素溶媒に懸濁させ、その懸濁液をハロゲン化チタンと接触、反応させて固体生成物を得、該固体生成物を炭化水素溶媒で洗浄後、さらに炭化水素溶媒の存在下、ハロゲン化チタンを接触させて固体触媒成分(I)を得る方法。
(11)ステアリン酸マグネシウムのような脂肪族マグネシウムを、ハロゲン化チタン及び成分(A)および必要に応じて成分(B)と接触反応させ、その後更にハロゲン化チタンと接触させることにより固体触媒成分(I)を調製する方法。
(12)ジアルコキシマグネシウムを炭化水素溶媒に懸濁させ、ハロゲン化チタンと接触させた後昇温し、成分(A)および必要に応じて成分(B)と同時にあるいは逐次的に接触反応させて固体生成物を得、該固体生成物を炭化水素溶媒で洗浄した後、炭化水素溶媒の存在下、再度ハロゲン化チタンと接触させて固体触媒成分(I)を調製する方法であって、上記懸濁・接触並びに接触反応のいずれかの段階において、塩化アルミニウムを接触させて固体触媒成分(I)を調製する方法。尚、追加で成分(B)による処理を加えても良い。
(13)ジアルコキシマグネシウム、2-エチルヘキシルアルコール及び二酸化炭素を、炭化水素溶媒の存在下で接触反応させて均一溶液とし、この溶液にハロゲン化チタン、成分(A)および必要に応じて成分(B)を同時にあるいは逐次的に接触反応させて固体物を得、更にこの固体物をテトラヒドロフランに溶解させ、その後更に固体生成物を析出させ、この固体生成物にハロゲン化チタンを接触反応させ、必要に応じハロゲン化チタンとの接触反応を繰り返し行い、固体触媒成分(I)を調製する方法。なおこの際、上記接触・接触反応・溶解のいずれかの段階において、例えばテトラブトキシシラン等のケイ素化合物を使用することもできる。
(14)塩化マグネシウム、有機エポキシ化合物及びリン酸化合物を炭化水素溶媒中に懸濁させた後、加熱して均一溶液とし、この溶液に、カルボン酸無水物及びハロゲン化チタンを接触反応させて固体生成物を得、該固体生成物に成分(A)および必要に応じて成分(B)を同時にあるいは逐次的に接触させて反応させ、得られた反応生成物を炭化水素溶媒で洗浄した後、炭化水素溶媒の存在下、再度ハロゲン化チタンを接触させることにより固体触媒成分(I)を得る方法。
(15)ジアルコキシマグネシウム、チタン化合物、成分(A)および必要に応じて成分(B)を炭化水素溶媒の存在下に接触反応させ、得られた反応生成物にポリシロキサン等のケイ素化合物を接触反応させ、更にハロゲン化チタンを接触反応させ、次いで有機酸の金属塩を接触反応させた後、再度ハロゲン化チタンを接触させることにより固体触媒成分(I)を得る方法。
(16)ジアルコキシマグネシウム、成分(A)と必要に応じて成分(B)を炭化水素溶媒に懸濁させた後、昇温してハロゲン化ケイ素と接触させ、その後ハロゲン化チタンと接触させて固体生成物を得、該固体生成物を炭化水素溶媒で洗浄した後、炭化水素溶媒の存在下、再度ハロゲン化チタンと接触させてオレフィン類重合用固体触媒成分(I)を調製する方法。なおこの際、該固体成分を、炭化水素溶媒の存在下又は不存在下で加熱処理してもよい。
本発明で使用するプロピレン系ブロック共重合用触媒は、(I)固体触媒成分、(II)有機アルミニウム化合物(以下、単に「成分(G)」ということがある。)および(III)外部電子供与性化合物(以下、単に「成分(H)」ということがある。)から形成される。なお、固体触媒成分(I)が、上記Si-O-C結合を有する有機ケイ素化合物、Si-N-C結合を有する有機ケイ素化合物又は上記有機アルミニウム化合物(反応試剤)を含む場合、あるいは反応試剤を含む固体触媒成分が、更に一般式(6)で表される有機ケイ素化合物を含む場合、成分(H)の使用を省略することができる。成分(H)を使用せずとも、固体触媒成分と、有機アルミニウムで形成される触媒が、重合活性や水素応答性に優れた性能を示すからである。
R4Si(OR5)4-q (3)
(式中、R4は炭素数1~12のアルキル基、ビニル基、炭素数3~12のアルケニル基、炭素数3~12のシクロアルキル基あるいはシクロアルケニル基、炭素数6~15の芳香族炭化水素基あるいは置換基を有する芳香族炭化水素基を示し、同一または異なっていてもよい。R5は炭素数1~4のアルキル基、ビニル基、炭素数3~12のアルケニル基、炭素数3~6のシクロアルキル基、または炭素数6~12の芳香族炭化水素基あるいは置換基を有する炭素数7~12の芳香族炭化水素基を示し、同一または異なっていてもよく、qは0≦q≦3の整数である。)で表される有機ケイ素化合物が挙げられる。
(R6R7N)sSiR8 4-s (4)
(式中、R6とR7は水素原子、炭素数1~20のアルキル基、ビニル基、炭素数3~20のアルケニル基、炭素数3~20のシクロアルキル基あるいはシクロアルケニル基または炭素数6~20のアリール基を示し、R6とR7は同一でも異なってもよく、また互いに結合して環を形成してもよい。R8は炭素数1~20のアルキル基、ビニル基、炭素数3~12のアルケニル基、炭素数1~20のアルコキシ基、ビニルオキシ基、炭素数3~20のアルケニルオキシ基、炭素数3~20のシクロアルキル基あるいはシクロアルキルオキシ基、または炭素数6~20のアリール基あるいはアリールオキシ基を示し、R8が複数ある場合、複数のR8は同一でも異なってもよい。sは1から3の整数である。)で表わされるアミノシラン化合物が挙げられる。
R9OCH2CR10R11CH2OR12 (5)
(式中、R10およびR11は水素原子、ハロゲン原子、炭素数1~12のアルキル基、ビニル基、炭素数3~12のアルケニル基、炭素数3~12のシクロアルキル基あるいはシクロアルケニル基、炭素数6~12の芳香族炭化水素基あるいはハロゲン置換芳香族炭化水素基、置換基を有する炭素数7~12の芳香族炭化水素基、炭素数1~12のアルキルアミノ基または炭素数2~12のジアルキルアミノ基を示し、同一または異なっていてもよく、互いに結合して環を形成してもよい。R9およびR12は炭素数1~12のアルキル基、ビニル基、炭素数3~12のアルケニル基、炭素数3~6のシクロアルキル基、炭素数6~12の芳香族炭化水素基あるいはハロゲン置換芳香族炭化水素基または置換基を有する炭素数7~12の芳香族炭化水素基を示し、同一または異なっていてもよい。)で表されるジエーテル化合物から選択される。
本発明においては、前記共重合触媒の存在下に、プロピレンとα-オレフィンの共重合を行ない、プロピレン系ブロック共重合体を製造する。α-オレフィンは、炭素数2~20のα-オレフィン(炭素数3のプロピレンを除く)から選ばれる少なくても1種のオレフィンであり、例えば、エチレン、1-ブテン、1-ペンテン、4-メチル-1-ペンテン、ビニルシクロヘキサン等が挙げられ、これらのα-オレフィン類は1種あるいは2種以上併用することができ、中でもエチレンおよび1-ブテンが好適に用いられる。特に好ましいものはエチレンである。
一般的には、ブロック共重合体とは、2種以上のモノマー組成が連続して変化するセグメントを含む重合体であり、モノマー種、コモノマー種、コモノマー組成、コモノマー含量、コモノマー配列、立体規則性などポリマーの一次構造の異なるポリマー鎖(セグメント)が1分子鎖中に2種類以上繋がっている形態のものをいうが、本発明の方法で得られるプロピレン系ブロック共重合体は、異なったモノマー組成の重合体が多段階重合により製造されたものであり、ポリマー鎖としてつながっているものも一部含んでいるものの、主要部分は異なるモノマー組成で得られた2種類以上の重合体が個々の重合ポリマー粒子内に混合して存在するものとなっている。
次に、実施例を挙げて本発明をさらに具体的に説明するが、これは単に例示であって、本発明を制限するものではない。なお、以下に示す実施例および比較例において、ジアルコキシマグネシウム粒子の円形度、固体触媒成分中のマグネシウム原子、チタン原子、ハロゲン原子および内部電子供与性化合物の含有量は、以下の方法により測定したものである。
ジアルコキシマグネシウム粒子の円形度は、ジアルコキシマグネシウム粒子を走査型電子顕微鏡(日本電子株式会社製、JSM-7500F)により、500~1000個の粒子が一画面に表示される程度の倍率で撮影し、撮影した粒子の中から無作為に500個以上を抽出し、画像解析処理ソフト(株式会社MOUNTECH製、MacView バージョン4.0)により各粒子の面積Sと周囲長Lを測定した後、各ジアルコキシマグネシウム粒子の円形度を下記式により算出したときの算術平均値として求めた。
各ジアルコキシマグネシウム粒子の円形度=4π×S÷L2
固体触媒成分中のマグネシウム原子の含有量は、予め加熱減圧乾燥により溶媒成分を完全に除去した固体触媒成分を秤量後、塩酸溶液で溶解し、指示薬のメチルオレンジと飽和塩化アンモニウム溶液を加え、アンモニア水で中和後に加熱し、冷却後に一定容としたものをろ別して沈殿物(Tiの水酸化物)を除去し、得られたろ液を一定量分取し、加熱後に緩衝液とEBT混合指示薬を加え、EDTA溶液で滴定するEDTA滴定方法により測定した。
固体触媒成分中のチタン原子含有量は、JIS 8311-1997「チタン鉱石中のチタン定量方法」に記載の方法(酸化還元滴定)に準じて測定した。
固体触媒成分中のハロゲン原子含有量は、予め加熱減圧乾燥により溶媒成分を完全に除去した固体触媒成分を秤量し、硫酸と純水の混合溶液で処理して水溶液とした後に一定容としたものを所定量分取し、自動滴定装置(平沼産業株式会社製、COM-1500)を用い、硝酸銀標準溶液でハロゲン原子を滴定する硝酸銀滴定法により測定した。
固体触媒成分中に含まれる第一の内部電子供与体~第三の内部電子供与性化合物の含有量は、ガスクロマトグラフィー((株)島津製作所製、GC-14B)を用いて下記の条件にて測定することで求めた。また、各成分(各内部電子供与性化合物)のモル数については、ガスクロマトグラフィーの測定結果より、予め既知濃度において測定した検量線を用いて求めた。
<測定条件>
カラム:パックドカラム(φ2.6×2.1m, Silicone SE-30 10%,Chromosorb WAW DMCS 80/100、ジーエルサイエンス(株)社製)
検出器:FID(Flame Ionization Detector,水素炎イオン化型検出器)
キャリアガス:ヘリウム、流量40ml/分
測定温度:気化室280℃、カラム225℃、検出器280℃、または気化室265℃、カラム180℃、検出器265℃
<2-エトキシエチル-1-フェニルカーボネートの合成>
クロロ蟻酸フェニル50gと2-エトキシエタノール33mlをジクロロメタン300mlに溶解させ、氷水にて0度に冷却した後、トリエチルアミン48mlを30分かけて滴下した。滴下終了後1時間かけてゆっくり室温まで昇温し、その後12時間反応させた。反応終了後、該反応物をカラム分離および蒸留により精製した結果、21gの反応生成物を得た。
<2-エトキシエチル-1-エチルカーボネートの合成>
ピリジン54mlと2-エトキシエタノール30gをジクロロメタン500mlに溶解させ、氷水にて0度に冷却した後、クロロ蟻酸エチル54gを30分かけて滴下した。滴下終了後1時間かけてゆっくり室温まで昇温し、その後16時間反応させた。反応終了後、該反応物をカラム分離および蒸留により精製した結果、53gの反応生成物を得た。
<2-エトキシエチル-1-メチルカーボネートの合成>
ジメチルカーボネート700gと炭酸カリウム230gの混合液に2-エトキシエタノール100gを窒素下、25℃で滴下した。添加後、16時間攪拌し、ろ過によりろ液を回収し、濃縮後、減圧蒸留により精製した結果、74gの反応生成物を得た。
<2-メトキシエチル-1-メチルカーボネートの合成>
ジメチルカーボネート830gと炭酸カリウム270gの混合液に2-メトキシエタノール100gを窒素下、25℃で滴下した。添加後、16時間攪拌し、ろ過によりろ液を回収し、濃縮後、減圧蒸留により精製した結果、61gの反応生成物を得た。
<2-エトキシエチル-1-(p-メチルフェニル)カーボネートの合成>
2-エトキシエタノール29gとジクロロメタン1000mlとの溶液にピリジン62.7gを0℃で加えた。さらに、p-トルイルクロロ蟻酸45gを0℃で滴下した。反応溶液は、20℃で16時間攪拌後、水で反応を停止し、ジクロロメタンで有機層を抽出した。抽出液は、塩水および炭酸水素ナトリウム水溶液で洗浄し、濃縮後、減圧蒸留により精製した結果、41gの反応生成物を得た。
<固体触媒成分(A1)の合成>
攪拌装置を備え、窒素ガスで充分に置換された内容積500mlのフラスコに、球状のジエトキシマグネシウム(円形度:1.10)10g(87.4ミリモル)を分取し、トルエン55mlを加えて懸濁状態とし、次いで該懸濁液に四塩化チタン30ml、2-エトキシエチル-1-フェニルカーボネート15.3ミリモル(3.21g)を加え、さらに昇温して90℃とした。その後、90℃の温度を保持した状態で90分反応させた。反応終了後、上澄みを抜き出しTiCl4を20ml追加し、さらに100℃で2時間反応させた。反応終了後、反応生成物を100℃のトルエン75mlで4回洗浄した。ついで40℃のn-ヘプタン75mlで6回洗浄して固体触媒成分(A1)を得た。固液分離後、固体触媒成分中のチタン含有量を測定したところ3.2重量%であった。
窒素ガスで完全に置換された内容積2.0リットルの撹拌機付オートクレーブに、トリエチルアルミニウム2.4ミリモル、ジシクロペンチルジメトキシシラン(DCPDMS)0.24ミリモルおよび上記固体触媒成分(A1)をチタン原子換算で0.003ミリモル装入し、エチレン-プロピレン共重合触媒(B1)を調製した。
上記エチレン-プロピレン共重合触媒(B1)10.2mgを攪拌機付オートクレーブに装入し、さらに液化プロピレン15モルと水素ガス0.20MPa(分圧)を装入し、20℃で5分間予備重合を行なった後、70℃で75分間、一段目のホモプロピレン(ホモ段)重合反応を行なった。ホモ段重合終了後、反応機の温度を室温に下げつつモノマーをパージし、その後オートクレーブ全体の重量を計量することで、重合開始前にあらかじめ秤量した重量との差から前段の重合量を求めた。窒素下でMFR測定用に一部のポリマーをサンプリングした後、再度モノマー供給ライン等を接続し、エチレン/プロピレン/水素を、それぞれモル比が1.0/1.0/0.043となるように上記撹拌機付オートクレーブ内に投入した後、70℃まで昇温し、エチレン/プロピレン/水素を、それぞれリットル/分が2/2/0.086の割合となるように導入しつつ、1.2MPa、70℃、1時間の条件で重合反応させることにより、プロピレン系ブロック共重合体を得た。
固体触媒成分1g当たりのプロピレン系ブロック共重合活性を、下記式により求めた。
プロピレン系ブロック共重合活性(g-ICP/g-触媒)
=(I(g)-F(g)+J(g))/[{オレフィン類重合用触媒中の固体触媒成分の質量(g)×((G(g)-F(g)-J(g))}/(G(g)-F(g)))]
ここで、Iは共重合反応終了後のオートクレーブ質量(g)、Fはオートクレーブ質量(g)、GはホモPP重合終了後、未反応モノマーを除去した後のオートクレーブ質量(g)、Jはホモ重合後に抜き出したポリマー量(g)である。
ブロック率(質量%)={(I(g)-G(g)+J(g))/(I(g)-F(g))}×100
ここで、Iは共重合反応終了後のオートクレーブ質量(g)、GはホモPP重合終了後、未反応モノマーを除去した後のオートクレーブ質量(g)、Jはホモ重合後に抜き出したポリマー量(g)、Fはオートクレーブ質量(g)である。
攪拌装置を具備したフラスコ内に、5.0gの共重合体(ICPプロピレン重合体)と、250mlのp-キシレンを装入し、外部温度をキシレンの沸点以上(約150℃)とすることにより、フラスコ内部のp-キシレンの温度を沸点下(137~138℃)に維持しつつ、2時間かけて重合体を溶解した。その後1時間かけて液温を23℃まで冷却し、不溶解成分と溶解成分とを濾過分別した。上記溶解成分の溶液を採取し、加熱減圧乾燥によりp-キシレンを留去し、得られた残留物の重量を求め、生成した重合体(プロピレン系ブロック共重合体)に対する相対割合(質量%)を算出して、EPR含量とした。
EPR中のエチレン含量は、上記EPR含量(ICP重合体中のキシレン可溶分量)測定操作においてキシレン抽出して得たEPR部(キシレン可溶分)を少量サンプリングし、ホットプレスにてフィルム状に成形した後、フーリエ変換赤外分光装置(FT-IR)(Thermonicolet製、Avatar)を用いて測定した吸光度とフィルムの厚みから、複数の含量既知サンプルより作成した検量線をもとに算出した。
測定波長:720cm-1および1150cm-1
フィルム厚み:0.1~0.2mm
上記でキシレン抽出して得たキシレン不溶部を少量サンプリングし、ホットプレスにてフィルム状に成形した後、上記EPR中のエチレン含量と同様にして、キシレン不溶分中のエチレン含量を算出した。
ホモポリプロピレンならびにICP重合体の溶融流れ性を示すメルトフローレート(MFR)(g/10分間)を、ASTM D 1238、JIS K 7210に準じて測定した。
JIS K 7171に従い、上記重合体を用いて物性測定用の試験片を成形し、23℃に調節された恒温室内で、状態調節を144時間以上行なった後、表面に液体や粉体の滲出が認められなかったものを試験片として用い、試験片の曲げ弾性率(FM)(MPa)を測定した。なお、試験片の成形は、得られたエチレン-プロピレン共重合体に対し、IRGANOX 1010(BASF社製)0.10重量%、IRGAFOS 168(BASF社製)0.10重量%、およびステアリン酸カルシウム0.08重量%を配合し、単軸押出機にて混練造粒してペレット状のエチレン-プロピレン共重合体を得、次いで、上記ペレット状の共重合体を、金型温度60℃、シリンダー温度230℃に保持した射出成形機に導入し、射出成形により実施した。
得られたエチレン-プロピレン共重合体に対し、IRGANOX 1010(BASF社製)0.10重量%、IRGAFOS 168(BASF社製)0.10重量%、およびステアリン酸カルシウム0.08重量%を配合し、単軸押出機にて混練造粒してペレット状のエチレン-プロピレン共重合体を得た。次いで、上記ペレット状の共重合体を、金型温度60℃、シリンダー温度230℃に保持した射出成形機に導入し、射出成形により物性測定用の試験片を射出成形した。成型後の試験片について、23℃に調節された恒温室内で、状態調節を144時間以上行った後、IZOD試験機(株式会社東洋精機製作所製、アイゾット衝撃試験機 型番A-121804405)を用い、JIS K7110「アイゾット衝撃強さの試験方法」に従い、試験片のアイゾット衝撃強度を測定した。試験片形状:ISO 180/4A、厚さ3.2mm、幅12.7mm、長さ63.5mmノッチ形状:タイプAノッチ(ノッチ半径0.25mm)、ノッチ付き金型にて形成した。
温度条件:23℃および-30℃
衝撃速度:3.5m/s
公称振り子エネルギー:23℃測定時 5.5J、-30℃測定時 2.75J
<重合触媒(B2)の形成およびプロピレン系ブロック共重合体の製造>
ジシクロペンチルジメトキシシラン(DCPDMS)0.24ミリモルに代えて、ジイソプロピルジメトキシシラン(DIPDMS)0.24ミリモルを用いた以外は、実施例1と同様にして重合触媒(B2)の形成および重合評価を行なった。重合結果を表1に示した。
<固体触媒成分(A3)の合成>
2-エトキシエチル-1-フェニルカーボネートに代えて、製造例2において得られた2-エトキシエチル-1-エチルカーボネートを同モル用いた以外は、実施例1と同様に固体触媒成分(A3)を調製した。得られた固体触媒成分中のチタン含有量は1.6重量%であった。
固体触媒成分(A1)に代えて、固体触媒成分(A3)を用いた以外は、実施例1と同様にして、重合触媒(B3)の形成および重合を行なった。重合結果を表1に示した。
<固体触媒成分(A4)の調製>
充分に窒素で置換した500ml丸底フラスコに、精製したn-ヘプタン120mlを導入した。更に、無水塩化マグネシウム15g、テトラブトキシチタンを106ml添加し、90℃で1.5時間反応させ均一な溶解液とした。次いで均一な溶解液を40℃に冷却した。40℃に保持したままメチルハイドロジェンポリシロキサン(20センチストークスのもの)を24ml添加し、5時間析出反応を行った。析出した固体生成物を精製したn-ヘプタンで充分に洗浄した。次いで、窒素で充分に置換した攪拌装置を備えた容量500ml丸底フラスコに、析出した固体生成物を40g導入し、更に精製したn-ヘプタンを導入して、固体生成物の濃度が200mg/mlとなる様にした。ここに、SiCl4を12ml添加して、90℃で3時間反応を行った。反応生成物を精製したn-ヘプタンで充分に洗浄し、反応生成物の濃度が100mg/mlとなる様に精製したn-ヘプタンを導入した。
固体触媒成分(A1)に代えて、固体触媒成分(A4)を使用した以外は、実施例1と同様の方法により、重合触媒(B4)の形成および重合を行なった。得られた固体触媒成分中のチタン含有量は2.9重量%であった。重合結果を表1に示した。
<固体触媒成分(a1)の調製>
2-エトキシエチル-1-フェニルカーボネート15.3ミリモルに代えて、ジブチルフタレート15.3ミリモルを用いた以外は、実施例1と同様にして固体触媒成分(a1)を調製した。得られた固体触媒成分のチタン含有量は3.7重量%であった。
固体触媒成分(A1)に代えて、固体触媒成分(a1)を使用した以外は、実施例1と同様の方法により、重合触媒(b1)の形成および重合を行なった。重合結果を表1に示した。
<固体触媒成分(a2)の調製>
2-エトキシエチル-1-フェニルカーボネートに代えて、2-イソプロピルー2-イソペンチルー1,3-ジメトキシプロパンを同モル用いた以外は、実施例1と同様に固体触媒成分(a2)を調製した。得られた固体触媒成分中のチタン含有量は2.5重量%であった。
固体触媒成分(A1)に代えて、固体触媒成分(a2)を用いた以外は、実施例1と同様にして、重合触媒(b2)の形成および重合を行なった。重合結果を表1に示した。
<固体触媒成分(A5)の調製>
2-エトキシエチル-1-フェニルカーボネートに代えて、製造例3において得られた2-エトキシエチル-1-メチルカーボネートを同モル用いた以外は、実施例1と同様にして固体触媒成分(A5)を調製した。得られた固体触媒成分中のチタン含有量は1.7重量%であった。
固体触媒成分(A1)に代えて、固体触媒成分(A5)を使用した以外は、実施例1と同様の方法により、重合触媒(B5)の形成および重合を行なった。重合結果を表1に示した。
<固体触媒成分(A6)の調製>
2-エトキシエチル-1-フェニルカーボネートに代えて、製造例4において得られた2-メトキシエチル-1-メチルカーボネートを同モル用いた以外は、実施例1と同様にして固体触媒成分(A6)を調製した。得られた固体触媒成分中のチタン含有量は1.5重量%であった。
固体触媒成分(A1)に代えて、固体触媒成分(A6)を使用した以外は、実施例1と同様の方法により、重合触媒(B6)の形成および重合を行なった。重合結果を表1に示した。
<固体触媒成分(A7)の調製>
2-エトキシエチル-1-フェニルカーボネートに代えて、製造例5において得られた2-エトキシエチル-1-(p-メチルフェニル)カーボネートを同モル用いた以外は、実施例1と同様にして固体触媒成分(A7)を調製した。得られた固体触媒成分中のチタン含有量は2.7重量%であった。
固体触媒成分(A1)に代えて、固体触媒成分(A7)を使用した以外は、実施例1と同様の方法により、重合触媒(B7)の形成および重合を行なった。重合結果を表1に示した。
<固体触媒成分(A8)の調製>
攪拌装置を備え、窒素ガスで充分に置換された内容積200mlのフラスコに、実施例1で得られた固体触媒成分5.6gおよびヘプタン70mlを装入して懸濁液を形成し、30℃に加温した。そこに攪拌下、ジビニルジメチルシラン6mmol、トリエチルアルミニウム18mmolおよびジシクロペンチルジメトキシシラン6mmolを順次添加し、ヘプタン15mlを導入し、30℃で2時間反応を行った。反応終了後、上澄み液をデカンテーションにより除去し、フラスコ内の固体成分を30℃のヘプタン150mlで3回洗浄し、固体触媒成分(A8)を得た。この固体触媒成分を分析したところ、チタンが2.0重量%であった。
固体触媒成分(A1)に代えて、固体触媒成分(A8)を用い、ジシクロペンチルジメトキシシラン(DCPDMS)0.24ミリモルの添加を省略した以外は、実施例1と同様にして重合触媒(B8)の形成及び重合を行なった。すなわち、重合用触媒は、固体触媒成分(A8)とトリエチルアルミニウムから形成されるものである。重合結果を表1に示した。
<固体触媒成分(A9)の合成>
攪拌装置を備え、窒素ガスで充分に置換された内容積500mlのフラスコに、ジエトキシマグネシウム10g(87.4ミリモル)、トルエン55ml、四塩化チタン30ml、ジイソブチルマロン酸ジエチル15.3ミリモル(3.8g)を加え、昇温して100℃とした。その後100℃の温度を保持した状態で90分反応させた。反応終了後、反応生成物を100℃のトルエン75mlで4回洗浄した。次に、新たに四塩化チタン10容量%のトルエン溶液100mlと2-エトキシエチル-1-メチルカーボネート2.64ミリモルを加えて、100℃に昇温し、15分間攪拌し反応させ、反応後、生成物を100℃のトルエンで1回洗浄した。この操作をさらに2回行った後、40℃のn-ヘプタン75mlで6回洗浄して固体触媒成分(A9)を得た。この固体触媒成分(A9)の固液を分離して固体分中のチタン含有量、ジイソブチルマロン酸ジエチル含有量および2-エトキシエチル-1-メチルカーボネート含有量を測定したところ1.7重量%、7.7重量%および3.7重量%であった。
固体触媒成分(A1)に代えて、固体触媒成分(A9)を用いた以外は、実施例1と同様にして重合触媒(B9)の形成および重合評価を行なった。重合結果を表1に示した。
<固体触媒成分(A10)の合成>
攪拌装置を備え、窒素ガスで充分に置換された内容積500mlのフラスコに、ジエトキシマグネシウム10g(87.4ミリモル)、トルエン55ml、四塩化チタン30ml、ベンジリデンマロン酸ジエチル15.3ミリモルおよび炭酸(2-エトキシエチル)(p-メチルフェニル)2.2ミリモルを加え、昇温して100℃とした。その後100℃の温度を保持した状態で90分反応させた。反応終了後、反応生成物を100℃のトルエン75mlで4回洗浄した。次に、新たに四塩化チタン10容量%のトルエン溶液100mlを加えて、100℃に昇温し、15分間攪拌し反応させ、反応後、生成物を100℃のトルエンで1回洗浄した。この操作をさらに2回行った後、40℃のn-ヘプタン75mlで6回洗浄して固体触媒成分(A10)を得た。この固体触媒成分(A10)の固液を分離して固体分中のチタン含有量、ベンジリデンマロン酸ジエチル含有量および炭酸(2-エトキシエチル)(p-メチルフェニル)含有量を測定したところ2.2重量%、9.2重量%、3.1重量%であった。
固体触媒成分(A1)に代えて、固体触媒成分(A10)を用いた以外は、実施例1と同様にして重合触媒(B10)の形成および重合評価を行なった。重合結果を表1に示した。
<重合用触媒(B11)の形成及びプロピレン系ブロック共重合体の製造>
ジシクロペンチルジメトキシシラン(DCPDMS)0.24ミリモルに代えて、ジイソプロピルジメトキシシラン(DIPDMS)0.24ミリモルを用いた以外は、実施例10と同様にして重合触媒(B11)の形成および重合評価を行なった。重合結果を表1に示した。
<重合用触媒の形成及び>
ジシクロペンチルジメトキシシラン(DCPDMS)0.24ミリモルに代えて、ジエチルアミノトリエトキシシラン(DEATES)0.24ミリモルを用いた以外は、実施例1と同様にして重合触媒(B12)の形成および重合評価を行なった。重合結果を表1に示した。
固体触媒成分(A1)に代えて、比較例1で製造した固体触媒成分(a1)を用い、さらにジシクロペンチルジメトキシシラン(DCPDMS)0.24ミリモルに代えて、ジエチルアミノトリエトキシシラン(DEATES)0.24ミリモルを用いる以外は、実施例1と同様にして重合触媒(b3)の形成および重合評価を行なった。重合結果を表1に示した。
<プロピレン系ブロック共重合体の製造>
実施例3に示すブロック共重合を実施後、モノマーガスをパージし、全体重量を秤量し、2段目のエチレンプロピレン共重合体量を確認した。ついで再度モノマーラインを接続し、1-ブテンを10グラム添加した後、エチレン/プロピレン/水素を、それぞれモル比が2.0/1.0/0.086となるように上記撹拌機付オートクレーブ内に投入した後、70℃まで昇温し、内圧を1.2MPaとした後、エチレン/プロピレン/水素を、それぞれリットル/分が2/1/0.086の割合となるように導入しつつ、1.2MPa、70℃で、20分間重合させることによりプロピレン系ブロック共重合体を得た。結果を表1に示す。
<プロピレン系ブロック共重合体の製造>
重合触媒(B1)に代えて、実施例3で用いた重合触媒(B3)を用いたこと、また、後段の重合時間1時間に代えて、2時間としたこと以外は、実施例1と同様に反応を行い、プロピレン系ブロック共重合体を得た。結果を表1に示す。
<プロピレン系ブロック共重合体の製造>
重合触媒(B1)に代えて、実施例3で用いた重合触媒(B3)を用い、更に、実施例1のホモ段重合終了後のICP重合に代えて、下記のICP重合を行った以外は、実施例1と同様に反応を行い、プロピレン系ブロック共重合体を得た。結果を表1に示す。
(ICP重合)
ホモ段重合終了後、反応機の温度を室温に下げつつモノマーをパージし、その後オートクレーブ全体の重量を計量することで、重合開始前にあらかじめ秤量した重量との差から前段の重合量を求めた。窒素下でMFR測定用に一部のポリマーをサンプリングした後、再度モノマー供給ライン等を接続し、エチレン/プロピレン/水素を、それぞれモル比が1.0/1.0/0.043となるように上記撹拌機付オートクレーブ内に投入した後、70℃まで昇温し、エチレン/プロピレン/水素を、それぞれリットル/分が2/2/0.086の割合となるように導入しつつ、1.2MPa、70℃、30分の条件で重合反応させ、次いで、エチレン/プロピレン/水素を、それぞれリットル/分が2/1/0.04の割合となるように導入しつつ、1.2MPa、70℃、30分の条件で追加の重合反応させることにより、プロピレン系ブロック共重合体を得た。
Claims (6)
- (I)チタン、マグネシウム、ハロゲンおよび下記一般式(1);
R1O-C(=O)-O-Z-OR2 (1)
(式中、R1およびR2は、炭素数1~20の直鎖状アルキル基、炭素数3~20の分岐アルキル基、ビニル基、炭素数3~20の直鎖状アルケニル基または分岐アルケニル基、炭素数1~20の直鎖状ハロゲン置換アルキル基、炭素数3~20の分岐ハロゲン置換アルキル基、炭素数2~20の直鎖状ハロゲン置換アルケニル基、炭素数3~20の分岐ハロゲン置換アルケニル基、炭素数3~20のシクロアルキル基、炭素数3~20のシクロアルケニル基、炭素数3~20のハロゲン置換シクロアルキル基、炭素数3~20のハロゲン置換シクロアルケニル基、炭素数6~24の芳香族炭化水素基、炭素数6~24のハロゲン置換芳香族炭化水素基、結合末端が炭素原子である炭素数2~24の窒素原子含有炭化水素基、結合末端が炭素原子である炭素数2~24の酸素原子含有炭化水素基、結合末端が炭素原子である炭素数2~24のリン含有炭化水素基、または炭素数1~24のケイ素含有炭化水素基を示し、同一でも異なっていてもよく、但し、該炭素数2~24の窒素原子含有炭化水素基は、結合末端がC=N基であるもの、該炭素数2~24の酸素原子含有炭化水素基は、結合末端がカルボニル基であるもの、該炭素数2~24のリン含有炭化水素基は、結合末端がC=P基であるものをそれぞれ除く。Zは、炭素原子又は炭素鎖を介して結合する結合性基を示す。)で表される化合物を含有する固体触媒成分、
(II)下記一般式(2);
R3 pAlQ3-p (2)
(式中、R3は炭素数1~6のヒドロカルビル基を示し、複数個ある場合は、同一でも異なってもよく、Qは水素原子、炭素数1~6のヒドロカルビルオキシ基、あるいはハロゲン原子を示し、pは0<p≦3の実数である。)で表わされる有機アルミニウム化合物、および
(III)外部電子供与性化合物、から形成される共重合用触媒の存在下に、プロピレンとα-オレフィンを共重合することを特徴とするプロピレン系ブロック共重合体の製造方法。 - 前記(III)外部電子供与性化合物が、下記一般式(3);
R4 qSi(OR5)4-q (3)
(式中、R4は炭素数1~12のアルキル基、ビニル基、炭素数3~12のアルケニル基、炭素数3~12のシクロアルキル基あるいはシクロアルケニル基、炭素数6~15の芳香族炭化水素基あるいは置換基を有する芳香族炭化水素基を示し、同一または異なっていてもよい。R5は炭素数1~4のアルキル基、ビニル基、炭素数3~12のアルケニル基、炭素数3~6のシクロアルキル基、または炭素数6~12の芳香族炭化水素基あるいは置換基を有する炭素数7~12の芳香族炭化水素基を示し、同一または異なっていてもよく、qは0≦q≦3の整数である。)で表される有機ケイ素化合物および一般式(4);
(R6R7N)sSiR8 4-s (4)
(式中、R6とR7は水素原子、炭素数1~20のアルキル基、ビニル基、炭素数3~20のアルケニル基、炭素数3~20のシクロアルキル基あるいはシクロアルケニル基または炭素数6~20のアリール基を示し、R6とR7は同一でも異なってもよく、また互いに結合して環を形成してもよい。R8は炭素数1~20のアルキル基、ビニル基、炭素数3~12のアルケニル基、炭素数1~20のアルコキシ基、ビニルオキシ基、炭素数3~20のアルケニルオキシ基、炭素数3~20のシクロアルキル基あるいはシクロアルキルオキシ基、または炭素数6~20のアリール基あるいはアリールオキシ基を示し、R8が複数ある場合、複数のR8は同一でも異なってもよい。sは1から3の整数である。)で表されるアミノシラン化合物から選択される1種または2種以上であることを特徴とする請求項1に記載のプロピレン系ブロック共重合体の製造方法。 - 前記(III)外部電子供与性化合物が、フェニルトリメトキシシラン、n-ブチルトリメトキシシラン、シクロペンチルトリメトキシシラン、シクロヘキシルトリメトキシシラン、フェニルトリエトキシシラン、n-ブチルトリエトキシシラン、シクロペンチルトリエトキシシラン、シクロヘキシルトリエトキシシラン、t-ブチルメチルジメトキシシラン、t-ブチルエチルジメトキシシラン、ジイソプロピルジメトキシシラン、ジイソブチルジメトキシシラン、ジイソペンチルジメトキシシラン、ジフェニルジメトキシシラン、ジシクロペンチルジメトキシシラン、シクロヘキシルメチルジメトキシシラン、シクロヘキシルシクロペンチルジメトキシシラン、テトラメトキシシラン、テトラエトキシシラン、t-ブチルメチルビス(エチルアミノ)シラン、ジシクロヘキシルビス(エチルアミノ)シラン、ジシクロペンチルビス(エチルアミノ)シラン、ビス(パーヒドロイソキノリノ)ジメトキシシラン、ジエチルアミノトリメトキシシランまたはジエチルアミノトリエトキシシランであることを特徴とする請求項1または2に記載のプロピレン系ブロック共重合体の製造方法。
- 前記(III)外部電子供与性化合物が、下記一般式(5);
R9OCH2CR10R11CH2OR12 (5)
(式中、R10およびR11は水素原子、ハロゲン原子、炭素数1~12のアルキル基、ビニル基、炭素数3~12のアルケニル基、炭素数3~12のシクロアルキル基あるいはシクロアルケニル基、炭素数6~12の芳香族炭化水素基あるいはハロゲン置換芳香族炭化水素基、置換基を有する炭素数7~12の芳香族炭化水素基、炭素数1~12のアルキルアミノ基または炭素数2~12のジアルキルアミノ基を示し、同一または異なっていてもよく、互いに結合して環を形成してもよい。R9およびR12は炭素数1~12のアルキル基、ビニル基、炭素数3~12のアルケニル基、炭素数3~6のシクロアルキル基、炭素数6~12の芳香族炭化水素基あるいはハロゲン置換芳香族炭化水素基または置換基を有する炭素数7~12の芳香族炭化水素基を示し、同一または異なっていてもよい。)で表される1,3-ジエーテル化合物であることを特徴とする請求項1に記載のプロピレン系ブロック共重合体の製造方法。 - 前記1,3-ジエーテル化合物が、2-イソプロピル-2-イソブチル-1,3-ジメトキシプロパン、2-イソプロピル-2-イソペンチル-1,3-ジメトキシプロパン、または9,9-ビス(メトキシメチル)フルオレンであることを特徴とする請求項4に記載のプロピレン系ブロック共重合体の製造方法。
- プロピレン単独の重合あるいはプロピレンとエチレンとの共重合後、プロピレンとエチレン、あるいはプロピレンとα-オレフィンの共重合を行うことを特徴とする請求項1~請求項5のいずれか1項に記載のプロピレン系ブロック共重合体の製造方法。
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WO2016121549A1 (ja) * | 2015-01-30 | 2016-08-04 | 東邦チタニウム株式会社 | オレフィン類重合触媒の製造方法およびオレフィン類重合体の製造方法 |
EP3212711B1 (en) | 2014-10-27 | 2020-03-04 | Borealis AG | Heterophasic polypropylene with improved stiffness/impact balance |
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JP6670081B2 (ja) * | 2015-11-24 | 2020-03-18 | 東邦チタニウム株式会社 | オレフィン類重合用触媒の製造方法 |
CN110997738B (zh) * | 2017-06-27 | 2022-08-16 | 埃克森美孚化学专利公司 | 高冲击聚丙烯抗冲共聚物 |
WO2019004418A1 (ja) * | 2017-06-30 | 2019-01-03 | 三井化学株式会社 | プロピレン系重合体、その製造方法、プロピレン系樹脂組成物および成形体 |
US11149100B2 (en) | 2017-11-06 | 2021-10-19 | Exxonmobil Chemical Patents Inc. | Propylene-based impact copolymers and process and apparatus for production |
CN116018361A (zh) * | 2020-07-11 | 2023-04-25 | 格雷斯公司 | 丙烯丁烯共聚物及由其制备的组合物 |
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WO2015107708A1 (ja) * | 2014-01-20 | 2015-07-23 | 東邦チタニウム株式会社 | オレフィン類重合用固体触媒成分、その製造方法、オレフィン類重合用触媒およびオレフィン類重合体の製造方法 |
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EP3212711B1 (en) | 2014-10-27 | 2020-03-04 | Borealis AG | Heterophasic polypropylene with improved stiffness/impact balance |
WO2016121549A1 (ja) * | 2015-01-30 | 2016-08-04 | 東邦チタニウム株式会社 | オレフィン類重合触媒の製造方法およびオレフィン類重合体の製造方法 |
CN107207645A (zh) * | 2015-01-30 | 2017-09-26 | 东邦钛株式会社 | 烯烃类聚合催化剂的制造方法和烯烃类聚合物的制造方法 |
KR20170109576A (ko) * | 2015-01-30 | 2017-09-29 | 도호 티타늄 가부시키가이샤 | 올레핀류 중합 촉매의 제조 방법 및 올레핀류 중합체의 제조 방법 |
JPWO2016121549A1 (ja) * | 2015-01-30 | 2017-11-09 | 東邦チタニウム株式会社 | オレフィン類重合触媒の製造方法およびオレフィン類重合体の製造方法 |
US10392453B2 (en) | 2015-01-30 | 2019-08-27 | Toho Titanium Co., Ltd. | Production method for olefin-polymerization catalyst and production method for olefin polymer |
CN107207645B (zh) * | 2015-01-30 | 2020-01-17 | 东邦钛株式会社 | 烯烃类聚合催化剂的制造方法和烯烃类聚合物的制造方法 |
KR102462715B1 (ko) | 2015-01-30 | 2022-11-03 | 도호 티타늄 가부시키가이샤 | 올레핀류 중합 촉매의 제조 방법 및 올레핀류 중합체의 제조 방법 |
EP3325554B1 (en) | 2015-07-22 | 2020-05-27 | Borealis AG | Moulded articles with improved impact/stiffness balance |
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EP2963064A1 (en) | 2016-01-06 |
CN105008407B (zh) | 2018-03-06 |
BR112015020633A2 (pt) | 2017-07-18 |
BR112015020633B1 (pt) | 2021-09-14 |
KR102100006B1 (ko) | 2020-05-26 |
SA515360934B1 (ar) | 2016-08-28 |
EP2963064A4 (en) | 2016-10-05 |
ES2728535T3 (es) | 2019-10-25 |
JP6283653B2 (ja) | 2018-02-21 |
US10011669B2 (en) | 2018-07-03 |
JPWO2014132759A1 (ja) | 2017-02-02 |
CN105008407A (zh) | 2015-10-28 |
EP2963064B1 (en) | 2019-04-03 |
TWI607025B (zh) | 2017-12-01 |
US20160009836A1 (en) | 2016-01-14 |
SG11201506721TA (en) | 2015-09-29 |
KR20150125664A (ko) | 2015-11-09 |
TW201441271A (zh) | 2014-11-01 |
SG10201706714YA (en) | 2017-09-28 |
RU2015136253A (ru) | 2017-03-31 |
RU2660441C2 (ru) | 2018-07-06 |
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