Olefin polymerization with direct use of ansa-metallocene amide complexes as catalysts
AssigneeUniversity of Iowa Research Foundation
InventorsRichard F. Jordan, Il Kim
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Abstract
The process of preparing polyolefins using rac ansa-metallocene metal amide complexes directly by use of aluminum alkyl in combination with a cocatalyst.
Claims10
Catalysts for the high activity polymerization of α-olefins, comprising:
- an ansa-metallocene metal amide complex of the formula:
- wherein Cp independently and in each occurrence is cyclopentadienyl, indenyl, or fluorenyl, or a hydrocarbyl, alkyl, aryl, silyl, halo, halohydrocarbyl, hydrocarbylmetalloid, or halohydrocarbylmetalloid substituted derivative of said cyclopentadienyl, indenyl, or fluorenyl, X is a bridging group which links the Cp groups, M is a metal selected from the group consisting of Group 3, 4, and 5 metals, R and R′ are the same or different and are each hydrogen or hydrocarbyl radicals of from C1 to C20, or silyl radicals, and n is from 3 to 5;
- and
- an aluminum alkyl of the formula Al(R″′)3 wherein R″′ is C1 to C20 hydrocarbyl radical, and
- a cocatalyst selected from the group consisting of alumoxanes, triarylcarbenium salts, ammonium salts, silver salts, ferrocenium salts, tris(pentafluorophenyl)borane and magnesium dichloride wherein the ansa-metallocene metal amide and the aluminum alkyl are combined before the cocatalyst is added and wherein the order of combination forms a cationic ansa-metallocene alkyl complex active species wherein the active species has a high olefin polymerization activity.
A method of forming polymers of α-olefins using a high activity ansa-metallocene amide catalyst, an aluminum alkyl, said aluminum alkyl having the formula Al(R″′)3 wherein R″′ is C1 to C20 hydrocarbyl radical, and a cocatalyst selected from the group consisting of alumoxanes, triarylcarbenium salts, ammonium salts, silver salts, and ferrocenium salts, tris(pentafluorophenyl)borane and magnesium dichloride, said method comprising:
- preparing a catalyst composition which comprises a metal amide complex of the formula:
- wherein Cp independently and in each occurrence is cyclopentadienyl, indenyl, or fluorenyl, or a hydrocarbyl, alkyl, aryl, silyl, halo, halohydrocarbyl, hydrocarbylmetalloid, or halohydrocarbylmetalloid substituted derivative of said cyclopentadienyl, indenyl, or fluorenyl, X is a bridging group which links the Cp groups, M is a metal selected from the group consisting of Group 3, 4, and 5 metals, R and R′ are the same or different and are each hydrogen or hydrocarbyl radicals of from C1 to C20, or silyl radicals, and n is from 3 to 5;
- and
- an aluminum alkyl of the formula Al(R″′)3 wherein R″′ equals an alkyl group of C1 to C20 carbon atoms, and thereafter adding a cocatalyst selected from the group consisting of alumoxanes, triarylcarbenium salts, ammonium salts, silver salts, and ferrocenium salts, and tris(pentafluorophenyl)borane and magnesium chloride;
- and thereafter
- contacting the catalyst and cocatalyst composition with an α-olefin under conditions to effect polymerization wherein the catalyst is an ansa-metallocene alkyl compound and wherein the combination of catalyst and cocatalyst forms a cationic ansa-metallocene alkyl complex active species wherein the active species has a high olefin polymerization activity.
A method of preparing a catalyst comprising:
- mixing a metallocene amide complex with an aluminum alkyl of the formula Al(R″′)3 wherein R″′ is C1 to C8 alkyl to form a first mixture and thereafter
- mixing the first mixture with aluminoxane.
Dependencies are inferred from the claim text.