Patent Application
20050010039
This invention relates to a class of metal complexes containing a polycyclic, fused ring ligand containing one or more Group 15 or 16 atoms, and to polymerization catalysts derived from such complexes that are particularly suitable for use in a polymerization process for preparing homopolymers and copolymers of olefins or diolefins, including copolymers comprising two or more olefins or diolefins such as copolymers comprising an α-olefin and ethylene or a monovinyl aromatic monomer and ethylene.
Constrained geometry metal complexes and methods for their preparation are disclosed in U.S. Pat. No. 5,703,187. This publication also teaches the preparation of certain novel copolymers of ethylene and a hindered vinyl monomer, including monovinyl aromatic monomers, having a pseudo-random incorporation of the hindered vinyl monomer therein. Additional teachings of constrained geometry catalysts may be found in U.S. Pat. Nos. 5,321,106, 5,721,185, 5,374,696, 5,470,993, 5,541,349, and 5,486,632, as well as WO97/15583, and WO97/19463.
Certain highly active, polycyclic aromatic, metal complexes, especially derivatives of s-indacenyl or cyclopentaphenanthrenyl ligand groups are disclosed in U.S. Pat. Nos. 6,034,022 and 6,329,486. Additional complexes based on non-aromatic polycyclic ring systems were disclosed in Ser. No. 09/879,463, filed Jun. 12, 2001, published as US-A-2002/0062011, on May 23, 2002. Metallocenes with heteroatom containing delocalized fused ring systems are disclosed in WO01/53360, WO01/44318, WO01/47939, WO01/48039, WO01/48040, WO98/06728 and U.S. Pat. No. 6,268,444, and suggested in U.S. Ser. No. 10/124,269, published as US-A-2002/0151662, on Oct. 17, 2002.
Despite the advance in the art obtained by the foregoing metal complexes, catalysts possessing improved catalytic performance are still desired by the industry. In particular, it would be desirable to provide improved metal complexes that may be readily synthesized. Accordingly, it would be desirable if there were provided metal complexes having good catalytic properties combined with relative ease of synthesis.
According to the present invention there is provided a polycyclic, heteroatom containing fused ring compound corresponding to the formula: CpM(Z)(X)x(T)t(X′)x′ (I),
The above compounds may exist as isolated crystals, as a mixture with other compounds, in the form of a solvated adduct, dissolved in a solvent, especially an organic liquid solvent, in the form of a dimer, or as a chelated derivative, especially wherein the chelating agent is an organic material such as ethylenediaminetetraacetic acid (EDTA).
Also, according to the present invention, there is provided a catalyst for olefin polymerization comprising:
Further according to the present invention there is provided a process for the polymerization of olefins comprising contacting one or more C2-20 olefins, including cyclic olefins, under polymerization conditions with a catalyst comprising:
The present catalysts and polymerization processes are especially efficient for production of olefin homopolymers, copolymers of two or more olefins, in particular, copolymers of ethylene and a C3-8 α-olefin or a vinylaromatic monomer, such as styrene, and interpolymers of three or more such polymerizable monomers over a wide range of polymerization conditions, and especially at elevated temperatures. They are especially useful for the formation of ethylene homopolymers and copolymers of ethylene and one or more C3-8 α-olefins as well as copolymers of ethylene, propylene and a diene (EPDM copolymers). Examples of suitable diene monomers include ethylidenenorbornene, 1,4-hexadiene or similar conjugated or nonconjugated dienes.
The catalysts of this invention may also be supported on a solid material and used in olefin polymerization processes in a slurry or in the gas phase. The catalyst may be prepolymerized with one or more olefin monomers in situ in a polymerization reactor or in a separate process with intermediate recovery of the prepolymerized catalyst prior to the primary polymerization process. They may also be combined with one or more additional catalysts whether metallocene or conventional Ziegler-Natta catalysts and used together or sequentially in one or more than one polymerization reactors according to the present process. In addition to their use as polymerization catalysts, compounds according to the present invention may be used for hydroformulation, hydrogenation or oligomerization processes.
All reference to the Periodic Table of the Elements herein shall refer to the Periodic Table of the Elements, published and copyrighted by CRC Press, Inc., 1995. Also, any reference to a Group or Groups shall be to the Group or Groups as reflected in this Periodic Table of the Elements using the IUPAC system for numbering groups. For purposes of United States patent practice, the contents of any patent, patent application or publication referenced herein is hereby incorporated by reference in its entirety herein, especially with respect to its disclosure of organometallic structures, synthetic techniques and general knowledge in the art. As used herein the term “aromatic” refers to a polyatomic, cyclic, ring system containing (4δ+2) π-electrons, wherein δ is an integer greater than or equal to 1. The term “fused” as used herein with respect to a ring system containing two or more polyatomic, cyclic rings means that with respect to at least two rings thereof, at least one pair of adjacent atoms is included in both rings.
If appearing herein, the term “comprising” and derivatives thereof is not intended to exclude the presence of any additional component, step or procedure, whether or not the same is disclosed herein. In order to avoid any doubt, all compositions claimed herein through use of the term “comprising” may include any additional additive, adjuvant, or compound, unless stated to the contrary. In contrast, the term, “consisting essentially of” if appearing herein, excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability. The term “consisting of”, if used, excludes any component, step or procedure not specifically delineated or listed. The term “or”, unless stated otherwise, refers to the listed members individually as well as in any combination.
Desirably, the compounds of the invention contain a cyclopentadienyl ring fused to a 5-membered ring at positions adjacent to one or more nitrogen, sulfur or oxygen heteroatoms contained in said 5-membered ring.
Preferred compounds (metal complexes) of the invention are those corresponding to the formula:
wherein:
In a desirable embodiment, when x is 2, x′ is zero, M is in the +4 formal oxidation state (or M is in the +3 formal oxidation state if Y is —NR52 or —PR52), and X is an anionic ligand selected from the group consisting of halide, hydrocarbyl, hydrocarbyloxy, di(hydrocarbyl)amido, di(hydrocarbyl)phosphido, hydrocarbylsulfido, and silyl groups, as well as halo-, di(hydrocarbyl)amino-, hydrocarbyloxy-, and di(hydrocarbyl)phosphino-substituted derivatives thereof, said X group having up to 30 atoms not counting hydrogen,
In the metal complexes, preferred T groups are carbon monoxide; phosphines, especially trimethylphosphine, triethylphosphine, triphenylphosphine and bis(1,2-dimethylphosphino)ethane; P(OR4)3, wherein R4 is C1-20 hydrocarbyl; ethers, especially tetrahydrofuran; amines, especially pyridine, bipyridine, tetramethylethylenediamine (TMEDA), and triethylamine; olefins; and neutral conjugated dienes having from 4 to 40, preferably 5 to 40 carbon atoms. Complexes including neutral diene T groups are those wherein the metal is in the +2 formal oxidation state.
Further in reference to the metal complexes, X preferably is desirably selected from the group consisting of hydro, halo, hydrocarbyl, silyl, and N,N-dialkylamino-substituted hydrocarbyl. The number of X groups depends on the oxidation state of M, whether Z is divalent or not and whether any neutral diene groups or divalent X′ groups are present. The skilled artisan will appreciate that the quantity of the various substituents and the identity of Z are chosen to provide charge balance, thereby resulting in a neutral metal complex. For example, when Z is divalent, and x is zero, x′ is two less than the formal oxidation state of M. When Z contains one neutral two electron coordinate-covalent bonding site, and M is in a formal oxidation state of +3, x may equal zero and x′ equal 1, or x may equal 2 and x′ equal zero. In a final example, if M is in a formal oxidation state of +2, Z may be a divalent ligand group, whereupon x and x′ are both equal to zero and one neutral T ligand group may be present.
Highly preferred compounds of formula (I) are those wherein M is titanium.
Examples of suitable A moieties may be depicted graphically as follows:
More highly preferred compounds and metal complexes of formula (I) according to the present invention correspond to the formula:
Most highly preferably, R1 each occurrence is hydrogen,
Most preferred metal complexes according to formula (I) according to the invention are compounds corresponding to the following formulas:
wherein R1 is C1-30 hydrocarbyl, preferably methyl, or a C4-30 alkyl or aralkyl group containing a secondary or tertiary substitution pattern at the β-carbon thereof, most preferably methyl, 2,2-dimethylpropan-1-yl, 2,2-dimethylbutan-1-yl, 2,2-diethylpropan-1-yl, 2,2-diethylbutan-1-yl, benzyl or pentafluorophenylmethyl group.
The metal complexes can be prepared by combining a metal halide salt with the corresponding fused, polycyclic ring system ligand dianion in an inert diluent, or by combining a metal amide with the corresponding neutral fused, polycyclic ring system in an inert diluent. Optionally a reducing agent can be employed to produce the lower oxidation state complexes, and standard ligand exchange procedures can by used to produce different ligand substituents. Processes that are suitably adapted for use herein are well known to synthetic organometallic chemists. The syntheses are preferably conducted in a suitable noninterfering solvent at a temperature from −100 to 300° C., preferably from −78 to 100° C., most preferably from 0 to 50° C. By the term “reducing agent” herein is meant a metal or compound which, under reducing conditions causes the metal M, to be reduced from a higher to a lower oxidation state. Examples of suitable metal reducing agents are alkali metals, alkaline earth metals, aluminum and zinc, alloys of alkali metals or alkaline earth metals such as sodium/mercury amalgam and sodium/potassium alloy. Examples of suitable reducing agent compounds are sodium naphthalenide, potassium graphite, lithium alkyls, lithium or potassium alkadienyls; and Grignard reagents. Most preferred reducing agents are the alkali metals or alkaline earth metals, especially lithium and magnesium metal.
Suitable reaction media for the formation of the complexes include aliphatic and aromatic hydrocarbons, ethers, and cyclic ethers, particularly branched-chain hydrocarbons such as isobutane, butane, pentane, hexane, heptane, octane, and mixtures thereof; cyclic and alicyclic hydrocarbons such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof; aromatic and hydrocarbyl-substituted aromatic compounds such as benzene, toluene, and xylene, C1-4 dialkyl ethers, C1-4 dialkyl ether derivatives of (poly)alkylene glycols, and tetrahydrofuran. Mixtures of the foregoing are also suitable.
Illustrative metal complexes according to the present invention include:
The skilled artisan will recognize that additional members of the foregoing list, obtainable by substitution of known ligands or different Group 3-10 metals for those specifically named, are also included within the invention. Moreover, it should also be recognized that all possible electronic distributions within the molecule, such as η3, η4 or η5 are intended to be included by the foregoing named compounds.
The complexes are rendered catalytically active by combination with an activating cocatalyst or use of an activating technique, such as those that are previously known in the art for use with Group 4 metal olefin polymerization complexes. Suitable activating cocatalysts for use herein include polymeric or oligomeric alumoxanes, especially methylalumoxane, triisobutyl aluminum modified methylalumoxane, or isobutylalumoxane; neutral Lewis acids, such as C1-30 hydrocarbyl substituted Group 13 compounds, especially tri(hydrocarbyl)aluminum- or tri(hydrocarbyl)boron compounds and halogenated (including perhalogenated) derivatives thereof, having from 1 to 10 carbons in each hydrocarbyl or halogenated hydrocarbyl group, more especially perfluorinated tri(aryl)boron compounds, and most especially tris(pentafluorophenyl)borane; nonpolymeric, compatible, noncoordinating, ion forming compounds (including the use of such compounds under oxidizing conditions), especially the use of ammonium-, phosphonium-, oxonium-, carbonium-, silylium- or sulfonium-salts of compatible, noncoordinating anions, or ferrocenium salts of compatible, noncoordinating anions; bulk electrolysis (explained in more detail hereinafter); and combinations of the foregoing activating cocatalysts and techniques. A preferred ion forming compound is a tri(C1-20-hydrocarbyl)ammonium salt of a tetrakis(fluoroaryl)borate, especially a tetrakis(pentafluorophenyl)borate. The foregoing activating cocatalysts and activating techniques have been previously taught with respect to different metal complexes in the following references: EP-A-277,003, U.S. Pat. No. 5,153,157, U.S. Pat. No. 5,064,802, U.S. Pat. No. 5,321,106, U.S. Pat. No. 5,721,185, U.S. Pat. No. 5,350,723, U.S. Pat. No. 5,425,872, U.S. Pat. No. 5,625,087, U.S. Pat. No. 5,883,204, U.S. Pat. No. 5,919,983, U.S. Pat. No. 5,783,512, WO 99/15534, and U.S. Ser. No. 09/251,664, filed Feb. 17, 1999 (WO99/42467).
Combinations of neutral Lewis acids, especially the combination of a trialkylaluminum compound having from 1 to 4 carbons in each alkyl group and a halogenated tri(hydrocarbyl)boron compound having from 1 to 20 carbons in each hydrocarbyl group, especially tris(pentafluorophenyl)borane, further combinations of such neutral Lewis acid mixtures with a polymeric or oligomeric alumoxane, and combinations of a single neutral Lewis acid, especially tris(pentafluorophenyl)borane with a polymeric or oligomeric alumoxane are especially desirable activating cocatalysts. Preferred molar ratios of Group 4 metal complex:tris(pentafluoro-phenylborane:alumoxane are from 1:1:1 to 1:10:30, more preferably from 1:1:1.5 to 1:5:10.
Suitable ion forming compounds useful as cocatalysts in one embodiment of the present invention comprise a cation which is a Bronsted acid capable of donating a proton, and a compatible, noncoordinating anion, A−. As used herein, the term “noncoordinating” means an anion or substance which either does not coordinate to the Group 4 metal containing precursor complex and the catalytic derivative derived therefrom, or which is only weakly coordinated to such complexes thereby remaining sufficiently labile to be displaced by a neutral Lewis base. A noncoordinating anion specifically refers to an anion which when functioning as a charge balancing anion in a cationic metal complex does not transfer an anionic substituent or fragment thereof to said cation thereby forming neutral complexes. “Compatible anions” are anions which are not degraded to neutrality when the initially formed complex decomposes and are noninterfering with desired subsequent polymerization or other uses of the complex.
Preferred anions are those containing a single coordination complex comprising a charge-bearing metal or metalloid core which anion is capable of balancing the charge of the active catalyst species (the metal cation) which may be formed when the two components are combined. Also, said anion should be sufficiently labile to be displaced by olefinic, diolefinic and acetylenically unsaturated compounds or other neutral Lewis bases such as ethers or nitrites. Suitable metals include, but are not limited to, aluminum, gallium, niobium or tantalum. Suitable metalloids include, but are not limited to, boron, phosphorus, and silicon. Compounds containing anions which comprise coordination complexes containing a single metal or metalloid atom are, of course, well known and many, particularly such compounds containing a single boron atom in the anion portion, are available commercially.
Preferably such cocatalysts may be represented by the following general formula:
(L*-H)d+(A)d−
L* is a neutral Lewis base;
More preferably Ad− corresponds to the formula: [M′Q4]−;
wherein:
In a more preferred embodiment, d is one, that is, the counter ion has a single negative charge and is A−. Activating cocatalysts comprising boron which are particularly useful in the preparation of catalysts of this invention may be represented by the following general formula:
(L*-H)+(BQ4)−;
L* is as previously defined;
Q is a hydrocarbyl-, hydrocarbyloxy-, fluorohydrocarbyl-, fluorohydrocarbyloxy-, hydroxyfluorohydrocarbyl-, dihydrocarbylaluminumoxyfluorohydrocarbyl-, or fluorinated silylhydrocarbyl-group of up to 20 nonhydrogen atoms, with the proviso that in not more than one occasion is Q hydrocarbyl. Most preferably, Q is each occurrence a fluorinated aryl group, especially, a pentafluorophenyl group.
Preferred Lewis base salts are ammonium salts, more preferably trialkyl-ammonium- or dialkylarylammonium-salts containing one or more C12-40 alkyl groups. The latter cocatalysts have been found to be particularly suitable for use in combination with not only the present metal complexes but other Group 4 metallocenes as well.
Illustrative, but not limiting, examples of boron compounds which may be used as an activating cocatalyst in the preparation of the improved catalysts of this invention (as well as previously known Group 4 metal catalysts) are
tri-substituted ammonium salts such as:
Preferred trialkylammonium cations are methyldioctadecylammonium and dimethyloctadecylammonium. The use of the above Bronsted acid salts as activating cocatalysts for addition polymerization catalysts is known in the art, having been disclosed in U.S. Pat. Nos. 5,064,802, 5,919,983, 5,783,512 and elsewhere. Preferred dialkylarylammonium cations are fluorophenyldioctadecylammonium-, perfluoro-phenyldioctacecylammonium- and p-trifluoromethylphenyldi(octadecyl)ammonium cations. It should be noted that certain of the cocatalysts, especially those containing a hydroxyphenyl ligand in the borate anion, may require the addition of a Lewis acid, especially a trialkylaluminum compound, to the polymerization mixture or the catalyst composition, in order to form the active catalyst composition.
Another suitable ion forming, activating cocatalyst comprises a salt of a cationic oxidizing agent and a noncoordinating, compatible anion represented by the formula:
(Oxe+)d(Ad−)e.
Ad− and d are as previously defined.
Examples of cationic oxidizing agents include: ferrocenium, hydrocarbyl-substituted ferrocenium, Ag+ or Pb+2. Preferred embodiments of Ad− are those anions previously defined with respect to the Bronsted acid containing activating cocatalysts, especially tetrakis(pentafluorophenyl)borate. The use of the above salts as activating cocatalysts for addition polymerization catalysts is known in the art, having been disclosed in U.S. Pat. No. 5,321,106.
Another suitable ion forming, activating cocatalyst comprises a compound which is a salt of a carbenium ion and a noncoordinating, compatible anion represented by the formula:
{circle over (C)}+A−
A further suitable ion forming, activating cocatalyst comprises a compound which is a salt of a silylium ion and a noncoordinating, compatible anion represented by the formula:
R33Si(X′)q+A−
Preferred silylium salt activating cocatalysts are trimethylsilylium tetrakispentafluorophenylborate, triethylsilylium tetrakispentafluorophenylborate and ether substituted adducts thereof. The use of the above silylium salts as activating cocatalysts for addition polymerization catalysts is known in the art, having been disclosed in U.S. Pat. No. 5,625,087.
Certain complexes of alcohols, mercaptans, silanols, and oximes with tris(pentafluorophenyl)borane are also effective catalyst activators and may be used according to the present invention. Such cocatalysts are disclosed in U.S. Pat. No. 5,296,433.
Another class of suitable catalyst activators are expanded anionic compounds corresponding to the formula: (A1+a
A1 is a cation of charge +a1,
The foregoing cocatalysts (illustrated by those having imidazolide, substituted imidazolide, imidazolinide, substituted imidazolinide, benzimidazolide, or substituted benzimidazolide anions) may be depicted schematically as follows:
Examples of these catalyst activators include the trihydrocarbylammonium-, especially, methylbis(tetradecyl)ammonium- or methylbis(octadecyl)ammonium-salts of:
A further class of suitable activating cocatalysts include cationic Group 13 salts corresponding to the formula:
[M″Q12L′1′]+(Arf3M′Q2)−
Examples of the foregoing Group 13 metal salts are alumicinium tris(fluoroaryl)borates or gallicinium tris(fluoroaryl)borates corresponding to the formula: [M″Q12L′1′]+(Arf3BQ2)−, wherein M″ is aluminum or gallium; Q1 is C1-20 hydrocarbyl, preferably C1-8 alkyl; Arf is perfluoroaryl, preferably pentafluorophenyl; and Q2 is C1-8 alkyl, preferably C1-8 alkyl. More preferably, Q1 and Q2 are identical C1-8 alkyl groups, most preferably, methyl, ethyl or octyl.
The foregoing activating cocatalysts may also be used in combination. An especially preferred combination is a mixture of a tri(hydrocarbyl)aluminum or tri(hydrocarbyl)borane compound having from 1 to 4 carbons in each hydrocarbyl group or an ammonium borate with an oligomeric or polymeric alumoxane compound.
The molar ratio of catalyst/cocatalyst employed preferably ranges from 1:10,000 to 100:1, more preferably from 1:5000 to 10:1, most preferably from 1:1000 to 1:1. Alumoxane, when used by itself as an activating cocatalyst, is employed in large quantity, generally at least 100 times the quantity of metal complex on a molar basis. Tris(pentafluorophenyl)borane, where used as an activating cocatalyst is employed in a molar ratio to the metal complex of form 0.5:1 to 10:1, more preferably from 1:1 to 6:1 most preferably from 1:1 to 5:1. The remaining activating cocatalysts are generally employed in approximately equimolar quantity with the metal complex.
The catalysts, whether or not supported in any suitable manner, may be used to polymerize ethylenically unsaturated monomers having from 2 to 100,000 carbon atoms either alone or in combination. Preferred addition polymerizable monomers for use herein include olefins, diolefins and mixtures thereof. Preferred olefins are aliphatic or aromatic compounds containing vinylic unsaturation as well as cyclic compounds containing ethylenic unsaturation. Examples of the latter include cyclobutene, cyclopentene, norbornene, and norbornene derivatives that are substituted in the 5- and 6-positions with C1-20 hydrocarbyl groups. Preferred diolefins are C4-40 diolefin compounds, including ethylidene norbornene, 1,4-hexadiene, and norbornadiene. The catalysts and processes herein are especially suited for use in preparation of ethylene/1-butene, ethylene/1-hexene, ethylene/styrene, ethylene/propylene, ethylene/1-pentene, ethylene/4-methyl-1-pentene and ethylene/1-octene copolymers as well as terpolymers of ethylene, propylene and a nonconjugated diene, such as, for example, EPDM terpolymers.
Most preferred monomers include the C2-20 α-olefins, especially ethylene, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-octene, 1-decene, long chain macromolecular α-olefins, and mixtures thereof. Other preferred monomers include styrene, C1-4 alkyl substituted styrene, ethylidenenorbornene, 1,4-hexadiene, 1,7-octadiene, vinylcyclohexane, 4-vinylcyclohexene, divinylbenzene, and mixtures thereof with ethylene. Long chain macromolecular α-olefins are vinyl terminated polymeric remnants formed in situ during continuous solution polymerization reactions. Under suitable processing conditions such long chain macromolecular units are readily polymerized into the polymer product along with ethylene and other short chain olefin monomers to give small quantities of long chain branching in the resulting polymer.
Preferred monomers include a combination of ethylene and one or more comonomers selected from monovinyl aromatic monomers, 4-vinylcyclohexene, vinylcyclohexane, norbornadiene, ethylidene-norbornene, C3-10 aliphatic α-olefins (especially propylene, isobutylene, 1-butene, 1-hexene, 3-methyl-1-pentene, 4-methyl-1-pentene, and 1-octene), and C4-40 dienes. Most preferred monomers are mixtures of ethylene and styrene; mixtures of ethylene, propylene and styrene; mixtures of ethylene, styrene and a nonconjugated diene, especially ethylidenenorbornene or 1,4-hexadiene, and mixtures of ethylene, propylene and a nonconjugated diene, especially ethylidenenorbornene or 1,4-hexadiene.
In general, the polymerization may be accomplished at conditions well known in the prior art for Ziegler-Natta or Kaminsky-Sinn type polymerization reactions, that is, temperatures from 0-250° C., preferably 30 to 200° C. and pressures from atmospheric to 10,000 atmospheres. Suspension, solution, slurry, gas phase, solid state powder polymerization or other process condition may be employed if desired. A support, especially silica, alumina, or a polymer (especially poly(tetrafluoroethylene) or a polyolefin) may be employed, and desirably is employed when the catalysts are used in a gas phase polymerization process. The support is preferably employed in an amount to provide a weight ratio of catalyst (based on metal):support from 1:106 to 1:103, more preferably from 1:106 to 1:104.
In most polymerization reactions the molar ratio of catalyst:polymerizable compounds employed is from 10−12:1 to 10−1:1, more preferably from 10−9:1 to 10−5:1.
Suitable solvents use for solution polymerization are liquids that are substantially inert under process conditions encountered in their usage. Examples include straight and branched-chain hydrocarbons such as isobutane, butane, pentane, hexane, heptane, octane, and mixtures thereof; cyclic and alicyclic hydrocarbons such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof; perfluorinated hydrocarbons such as perfluorinated C4-10 alkanes, and alkyl-substituted aromatic compounds such as benzene, toluene, xylene, and ethylbenzene. Suitable solvents also include liquid olefins which may act as monomers or comonomers.
The catalysts may be utilized in combination with at least one additional homogeneous or heterogeneous polymerization catalyst in the same reactor or in separate reactors connected in series or in parallel to prepare polymer blends having desirable properties. An example of such a process is disclosed in WO 94/00500.
The catalysts of the present invention are particularly advantageous for the production of ethylene homopolymers and ethylene/α-olefin copolymers having high levels of long chain branching. The use of the catalysts of the present invention in continuous polymerization processes, especially continuous, solution polymerization processes, allows for elevated reactor temperatures which favor the formation of vinyl terminated polymer chains that may be incorporated into a growing polymer, thereby giving a long chain branch. The use of the present catalyst compositions advantageously allows for the economical production of ethylene/α-olefin copolymers having processability similar to high pressure, free radical produced low density polyethylene.
The present catalyst compositions may be advantageously employed to prepare olefin polymers having improved processing properties by polymerizing ethylene alone or ethylene/α-olefin mixtures with low levels of a “H” branch inducing diene, such as norbornadiene, 1,7-octadiene, or 1,9-decadiene. The unique combination of elevated reactor temperatures, high molecular weight (or low melt indices) at high reactor temperatures and high comonomer reactivity advantageously allows for the economical production of polymers having excellent physical properties and processability. Preferably such polymers comprise ethylene, a C3-20 α-olefin and a “H”-branching comonomer. Preferably, such polymers are produced in a solution process, most preferably a continuous solution process.
The catalyst composition may be prepared as a homogeneous catalyst by addition of the requisite components to a solvent or diluent in which polymerization will be conducted. The catalyst composition may also be prepared and employed as a heterogeneous catalyst by adsorbing, depositing or chemically attaching the requisite components on an inorganic or organic particulated solid. Examples of such solids include, silica, silica gel, alumina, clays, expanded clays (aerogels), aluminosilicates, trialkylaluminum compounds, and organic or inorganic polymeric materials, especially polyolefins. In a preferred embodiment, a heterogeneous catalyst is prepared by reacting an inorganic compound, preferably a tri(C1-4 alkyl)aluminum compound, with an activating cocatalyst, especially an ammonium salt of a hydroxyaryl(trispentafluorophenyl)borate, such as an ammonium salt of (4-hydroxy-3,5-ditertiarybutylphenyl)tris(pentafluorophenyl)borate or (4-hydroxyphenyl) tris(pentafluorophenyl)borate. This activating cocatalyst is deposited onto the support by coprecipitating, imbibing, spraying, or similar technique, and thereafter removing any solvent or diluent. The metal complex is added to the support, also by adsorbing, depositing or chemically attaching the same to the support, either subsequently, simultaneously or prior to addition of the activating cocatalyst.
When prepared in heterogeneous or supported form, the catalyst composition is employed in a slurry or gas phase polymerization. As a practical limitation, slurry polymerization takes place in liquid diluents in which the polymer product is substantially insoluble. Preferably, the diluent for slurry polymerization is one or more hydrocarbons with less than 5 carbon atoms. If desired, saturated hydrocarbons such as ethane, propane or butane may be used in whole or part as the diluent. Likewise, the α-olefin monomer or a mixture of different α-olefin monomers may be used in whole or part as the diluent Most preferably, at least a major part of the diluent comprises the α-olefin monomer or monomers to be polymerized. A dispersant, particularly an elastomer, may be dissolved in the diluent utilizing techniques known in the art, if desired.
At all times, the individual ingredients as well as the recovered catalyst components must be protected from oxygen and moisture. Therefore, the catalyst components and catalysts must be prepared and recovered in an oxygen and moisture free atmosphere. Preferably, therefore, the reactions are performed in the presence of an dry, inert gas, such as, for example, nitrogen.
The polymerization may be carried out as a batchwise or a continuous polymerization process. A continuous process is preferred, in which event catalyst, ethylene, comonomer, and optionally solvent, are continuously supplied to the reaction zone, and polymer product continuously removed therefrom.
Without limiting in any way the scope of the invention, one means for carrying out such a polymerization process is as follows: In a stirred-tank reactor, the monomers to be polymerized are introduced continuously, together with solvent and an optional chain transfer agent. The reactor contains a liquid phase composed substantially of monomers, together with any solvent or additional diluent and dissolved polymer. If desired, a small amount of a “H”-branch inducing diene such as norbornadiene, 1,7-octadiene or 1,9-decadiene may also be added. Catalyst and cocatalyst are continuously introduced in the reactor liquid phase. The reactor temperature and pressure may be controlled by adjusting the solvent/monomer ratio, the catalyst addition rate, as well as by cooling or heating coils, jackets or both. The polymerization rate is controlled by the rate of catalyst addition. The ethylene content of the polymer product is determined by the ratio of ethylene to comonomer in the reactor, which is controlled by manipulating the respective feed rates of these components to the reactor. The polymer product molecular weight is controlled, optionally, by controlling other polymerization variables such as the temperature, monomer concentration, or by the previously mention chain transfer agent, such as a stream of hydrogen introduced to the reactor, as is well known in the art. The reactor effluent is contacted with a catalyst kill agent such as water. The polymer solution is optionally heated, and the polymer product is recovered by flashing off gaseous monomers as well as residual solvent or diluent at reduced pressure, and, if necessary, conducting further devolatilization in equipment such as a devolatilizing extruder. In a continuous process the mean residence time of the catalyst and polymer in the reactor generally is from 5 minutes to 8 hours, and preferably from 10 minutes to 6 hours.
Ethylene homopolymers and ethylene/α-olefin copolymers are particularly suited for preparation according to the invention. Generally such polymers have densities from 0.85 to 0.96 g/ml. Typically the molar ratio of α-olefin comonomer to ethylene used in the polymerization may be varied in order to adjust the density of the resulting polymer. When producing materials with a density range of from 0.91 to 0.93 the comonomer to monomer ratio is less than 0.2, preferably less than 0.05, even more preferably less than 0.02, and may even be less than 0.01. In the above polymerization process hydrogen has been found to effectively control the molecular weight of the resulting polymer. Typically, the molar ratio of hydrogen to monomer is less than 0.5, preferably less than 0.2, more preferably less than 0.05, even more preferably less than 0.02 and may even be less than 0.01.
It is understood that the present invention is operable in the absence of any component which has not been specifically disclosed. The following examples are provided in order to further illustrate the invention and are not to be construed as limiting. Unless stated to the contrary, all parts and percentages are expressed on a weight basis. The term “overnight”, if used, refers to a time of approximately 16-18 hours, “room temperature”, if used, refers to a temperature of about 20-25° C., and “mixed alkanes” refers to a mixture of hydrogenated propylene oligomers, mostly C6-C12 isoalkanes, available commercially under the trademark Isopar E™ from Exxon Chemicals Inc. In the event any compound depicted by a structural formula is incorrectly named, the formula shall be controlling.
All solvents were purified using the technique disclosed by Pangborn et al, Organometallics, 15, 1518-1520, (1996). 1H and 13C NMR shifts were referenced to internal solvent resonances and are reported relative to TMS.
1-Phenylpyrrole-2-carbaldehyde In a nitrogen purged one liter flask equipped with a mechanical stirrer were placed 16.2 mL of dimethylformamide followed by slow addition of 19 mL of POCl3. The mixture was stirred for 10 minutes, then cooled to 0° C. To the mixture was added a solution of 25 g of 1-phenylpyrrole in 25 mL of dichloromethane. The mixture was allowed to warm to room temperature (10 minutes) and was then heated to 50° C. for one hour. The contents were then cooled to room temperature and the flask was opened to the air and 220 g of crushed ice were added, followed by 250 mL of 20 percent aqueous NaOH. The mixture was immediately warmed to 85° C. and stirred for 10 minutes, then the flask was cooled to room temperature using an ice bath. The reaction mixture was extracted with dichloromethane (3×100 mL) and the combined organic fractions were washed with water (2×200 mL). The organic fraction was then dried with sodium sulfate and the volatiles removed in a rotary evaporator to leave an orange oil (24.4 g, 82 percent). The product contained 10 percent of the 1-phenylpyrrole-3-carbaldehyde isomer, and was used without further purification.
1H NMR (CDCl3): 6.35 (dd, 1H), 7.0 (t, 1H), 7.1 (dd, 1H), 7.3 (m, 2H), 7.4 (m, 3H), 9.5 (s, 1H); 13C {1H} NMR (CDCl3) 178.4, 138.2, 132.0, 130.6, 128.6, 127.7, 125.5, 121.5, 110.4.
Ethyl-(2Z)-2-methyl-3-[1-phenylpyrrol-2-yl]prop-2-enoate Into a 250 mL flask, a solution of triethyl 2-phosphonopropionate (32 mL, 150 mmoles) in 20 mL of THF was added slowly to a mixture of sodium hydride (4.8 g, 200 mmoles) in 10 mL of THF at 0° C. The slurry was warmed to room temperature and stirred for one hour; the temperature was lowered to −10° C. Then a solution of 1-phenylpyrrole-2-carbaldehyde (24.4 g, 142 mmoles) in 50 mL of THF was added in a period of 10 minutes. The mixture slowly formed a precipitate. The precipitate was partially broken with a spatula and the reaction mixture was slowly warmed to room temperature over 30 minutes. A saturated aqueous solution of NH4Cl (20 mL) was carefully added. The product was extracted in ether (2×100 mL), the ether extracts washed with brine and dried over sodium sulfate. The solvent was removed in a rotary evaporator, and the crude product was washed with hexane to give an orange oil. The oil crystallized over a period of several days and was triturated with small portions of hexane (5×10 mL), filtered and the solid dried in vacuo to give 25.8 g (71 percent) of a light-tan crystalline material.
1H NMR (CDCl3): 7.4 (m, 4H), 7.3 (m, 2H), 7.0 (dd, 1H), 6.7 (dd, 1H), 6.4 (t, 1H), 4.1 (q, 2H), 2.2 (d, 3H), 1.2 (t, 3); 13C {1H} NMR (CDCl3) 168.8, 139.2, 129.6, 129.2, 127.6, 127.5, 126.3, 125.0, 122.9, 114.3, 110.2, 60.4, 14.3, 14.2.
Ethyl [2-Methyl-3-(1-phenylpyrrol-2-yl)]propanoate In a 300 mL Parr reactor were charged 12.0 g (47 mmoles) of ethyl-(2Z)-2-methyl-3-[1-phenylpyrrol-2-yl]prop-2-enoate, 0.6 g of 10 percent Pd on carbon and 150 mL of methylene chloride. The reactor was pressurized to 80 psig (660 kPa) with hydrogen; after one hour the pressure had dropped to 40 psig (380 kPa), the reactor was repressurized to 100 psig (790 kPa) with hydrogen and the mixture was stirred overnight. The next day the residual pressure of hydrogen was vented and the reactor was purged with nitrogen. The catalyst was filtered off and the filtrate was dried in a rotary evaporator to leave the product as a liquid: 12.5 g (103 percent).
1H NMR (CDCl3): 7.3-7.4 (m, 5H), 6.7 (m, 1H), 6.2 (m, 1H), 6.0 (m, 1H), 4.0 (q, 2H), 2.9 (m, 1H), 2.5 (m, 2H), 1.2 (t, 3H), 1.0 (d, 3H); 13C {1H} NMR (CDCl3) 175.8, 140.1, 130.7, 129.0, 127.1, 126.2, 121.8, 111.7, 107.9, 60.1, 39.4, 30.4, 17.0, 14.0.
2-Methyl-3-[1-phenylpyrrol-2-yl]propanoic acid In a 500 mL flask were placed 12.5 g (48.6 mmoles) of ethyl [2-methyl-3-(1-phenylpyrrol-2-yl)]propanoate, and then 250 mL of Claisen's alkali (350 g KOH+250 mL water; cool and dilute to one liter with methanol) was added. The mixture was heated to 90° C. for one hour. The yellowish solution was poured over crushed ice and then enough 6M HCl was added to acidify the solution to pH 1-2. The precipitated free acid was extracted with ether (3×300 mL), the ether washes with brine, and dried with anhydrous sodium sulfate. The volatiles were removed in a rotary evaporator. The product was recovered as a yellow liquid: 9.5 g (85 percent).
1H NMR (CDCl3): 9.6 (br, 1H), 7.3-7.4 (m, 5H), 6.7 (m, 1H), 6.2 (m, 1H), 6.1 (m, 1H), 3.5 (q, 2H), 3.0 (m, 1H), 2.6 (m, 2H), 1.2 (t, 3H), 1.1 (d, 3H); 13C {1H} NMR (CDCl3) 182.2, 140.0, 130.5, 129.1, 127.3, 126.3, 122.2, 108.1, 108.0, 65.8, 39.5, 30.0, 16.8, 15.1.
5,6-dihydro-5-methyl-1-phenylcyclopenta[b]pyrrol-4(1H)-one Super polyphosphoric acid (SPPA) was prepared by mixing 41 g of P2O5 in 250 g of polyphosphoric acid at 140° C. until all of the P2O5 dissolved. The SPPA was cooled to 100° C. and then a solution made with 9.5 g (41.4 mmoles) of 2-methyl-3-[1-phenylpyrrol-2-yl]propanoic acid, in 20 mL of 1,2-dichloroethane was added dropwise. The mixture was stirred for five hours, cooled to 60° C. and poured slowly onto water. After complete breakdown of the clumpy reaction mixture, the product was extracted with dichloromethane, the organic phase was washed with NaHCO3, and dried with Na2SO4. The volatiles were removed on a rotary evaporator, leaving a tan solid. Yield: 8.5 g (97 percent)
1H NMR (CDCl3): 1.34 (d, 3H), 2.65 (dd, 1H), 3.0 (pd, 1H), 3.3 (dd, 1H), 6.5 (d, 1H), 7.1 (d, 1H), 7.4 (m, 3H), 7.5 (m, 2H); 13C {1H} NMR (CDCl3): 17.0, 30.7, 47.4, 104.0, 121.9, 127.0, 127.8, 129.7, 138.6, 156.4, 199.5.
5,6-dihydro-5-methyl-1-phenylcyclopenta[b]pyrrol-4(1H)-one tosyl hydrazone A mixture containing 5,6-dihydro-5-methyl-1-phenylcyclopenta[b]pyrrol-4(1H)-one (8.5 g, 40.2 mmol), p-toluene sulfonyl hydrazide (7.7 g, 41 mmoles) and p-toluene sulfonic acid monohydrate (1 g, 5 mmoles) were stirred overnight in 60 mL of ethanol at 70° C. The solution was cooled in the freezer for a few hours and the precipitated product was collected, washed with ether and dried in vacuum to give a tan solid (7.7 g, 50 percent), m.p. 175-6° C.
1H NMR (CDCl3): 7.9 (d, 2H), 7.45 (m, 2H), 7.3 (m, 6H), 7.05 (d, 1H), 6.56 (d, 1H), 3.4 (pd, 1H), 3.2 (dd, 1H), 2.55 (dd, 1H), 2.4 (s, 3H), 1.25 (d, 3H); 13C {1H} NMR (CDCl3): 19.6, 21.5, 32.3, 42.7, 105.5, 121.3, 121.7, 126.3, 126.9, 128.1, 129.2, 129.7, 135.4, 138.8, 143.5, 147.1, 162.3.
1,6-Dihydro-5-methyl-1-phenylcyclopenta[b]pyrrole To a mixture of 5,6-dihydro-5-methyl-1-phenylcyclopenta[b]pyrrol-4(1H)-one tosyl hydrazone (7.55 g, 19.9 mmol) in 80 mL of THF was added 26 mL of n-BuLi (1.6 M, hexanes; 2.1 equiv., 41.8 mmoles) at −78° C. in about five minutes. The dark brown mixture was slowly allowed to warm up to room temperature, and was stirred overnight. A saturated solution of NH4Cl (10 mL) was carefully added, and the volatiles were removed in a rotary evaporator. Water (100 mL) was added to the solid residue and the mixture was extracted with ether (2×100 mL). The ether layers were combined and dried with Na2SO4, then the volatiles were removed in a rotary evaporator to leave 4.7 g of a brownish-yellow oil, to which was added 80 mL of hexane and the mixture stirred for 30 minutes; repeated the process once more. The filtered extracts were combined and dried in vacuo to give 2.4 g (62 percent) of an orange-yellow oil. NMR analysis showed the presence of two isomers.
1H NMR (CDCl3): 7.5 (m, 4H), 7.3 (m, 1H), 7.1 (d, 1H), 6.95* (d, 1H), 6.55* (br s, 1H), 6.4 (br s, 1H), 6.35* (d, 1H), 6.25 (d, 1), 3.3 (br s, H), 3.1* (br s, 1H), 2.21* (s, 3H), 2.15 (s, 3H); peaks marked with * are from the least abundant (40 percent)isomer in the final product.
1-(1,4-dihydro-5-methyl-1-phenylcyclopenta[b]pyrrol-4-yl)-N-1,1-dimethylethyl)-1,1-dimethylsilanamine To a mixture of 1,6-dihydro-5-methyl-1-phenylcyclopenta[b]pyrrole (2.41 g, 12.3 mmol) in 50 mL of hexanes were added 7.9 mL of butyl lithium (1.6 M hexane; 1.02 equiv.). The mixture was stirred overnight, filtered, the solid was washed with hexanes and dried 2.3 g (92 percent), then redissolved in 60 mL of THF. Then a solution of Me2SiCl(NHtBu) (1.94 g, 1.03 equiv.; 11.7 mmoles) in 20 mL of THF was added and the solution was stirred overnight. The volatiles were pumped off, the residue extracted with hexane, filtered and the filtrate was then dried in vacuo to give 3.75 g (94 percent) of a dark orange oil.
1H NMR (C6D6): 7.3 (m, 2H), 7.05 (m, 1H), 6.9 (m, 1H), 6.5 (m, 1H), 6.4 (d, 1H), 3.1 (s, 1H), 2.2 (s, 3H), 1.1 (s, 9H),m 0.5 (br s, 1H), 0.2 (s, 3H), −0.1 (s, 3H).
[1-[(3a,4,5,6,6a-η)-1,4-dihydro-5-methyl-1-phenylcyclopenta[b]pyrrol-4-yl)-N-(1,1-dimethylethyl-1,1-dimethylsilanamato(2-)-κN]dichloro titanium Into a 100 mL jar were placed 0.50 g (0.41 mmoles) of N-(1,1-dimethylethyl)-1-(1-phenyl-5-methyl-4H-cyclopenta[b]aza-4-yl)-1,1-dimethylsilanamine, 60 mL of hexane, and then 2.0 mL of BuLi (1.6M, hexanes) were added. The mixture was stirred overnight. A small amount of solid precipitated. The volatiles were removed in vacuo and the residues redissolved in 20 mL of THF. This was followed by addition of 0.57 g (0.41 mmoles) of TiCl3.3THF. The mixture was stirred for thirty minutes and then PbCl2 (300 mg, 1.3 electron equivalents) was added, followed by 10 mL of CH2Cl2. After one hour the volatiles were removed in vacuo. The residue was dissolved in hexane (60 mL) and filtered. The hexane insoluble brick-red material (0.69 g) was extracted with benzene, filtered and the filtrate dried in vacuo. Yield: 0.37 g (54 percent)
1H NMR (C6D6): 7.2 (d, 2H), 7.03 (t, 2H), 7.0 (d, 1H), 6.9 (t, 1H), 6.43 (s, 1H), 6.15 (d, 1H), 2.2 (s, 3H), 1.4 (s, 9H), 0.6 (s, 3H), 0.5 (s, 3H); 13C {1H} NMR (C6D6) 143.2, 135.2, 129.9, 126.0, 121.0, 107.3, 105.7, 61.5, 32.6, 20.0, 3.8, 3.4.
Into a 120 mL jar were placed 0.37 g (0.84 mmoles) of [1-[(3a,4,5,6,6a-η)-1,4-dihydro-5-methyl-1-phenylcyclopenta[b]pyrrol-4-yl)-N-(1,1-dimethylethyl)-1,1-dimethylsilanamato(2-)-κN]dichloro titanium (from example 1), 30 mL of ether and 40 mL of THF. Then 0.6 mL of MeMgI (3M, ether, 1.8 mmoles) were added. The mixture was stirred for one hour, the volatiles removed in vacuo, the residue extracted with hexane, filtered, dried in vacuo (0.33 g), redissolved once more in hexane and filtered, and the filtrate concentrated down to about 5 mL. The solution was placed overnight in the −30° C. freezer. The supernatant was separated from the crystals formed. Yield: 0.19 g of yellow crystals.
1H NMR (C6D6): 0.1 (s, 3H), 0.50 (s, 3H), 0.52 (s, 3H), 1.8 (s, 9H), 2.0 (s, 3H), 6.1 (d, 2H), 6.6 (s, 1H), 6.9 (t, 2H), 7.1 (m), 7.2 (d); 13C {1H} NMR (C6D6): 4.2, 4.8, 18.6, 34.5, 49.5, 55.7, 57.5, 83.8, 103.7, 105.8, 119.4, 124.7, 129.9, 130.4, 131.6, 137.7, 140.5.
3-bromo-2-methyl-thiophene A 500 mL flask was charged with 12 mL (85 mmol) of diisopropylamine, 150 mL of ether THF and the system capped with an addition funnel/septum and the system purged with nitrogen and cooled to 0° C. To this was added over 20 minutes 3.5 mL of nBuLi (85 mmol, 1.6 M in hexanes). After adding all the reagent, the reaction was stirred for an additional 15 minutes and then the solution cooled to −78° C. To this was added over 30 minutes a 100 mL THF solution containing 8 mL (85 mmol) of 3-bromo-thiophene. After the addition was complete, the solution was allowed to warm to 0° C. and stirred for 15 minutes. The solution was again cooled to −78° C. and to this added 5.4 mL (85 mmol) of iodomethane in 50 mL of THF. The solution was allowed to warm to room temperature and stirred for 1.5 hrs. The solution was cooled to 0° C. and quenched with 100 mL of 1 M HCl(aq). The water layer was separated and washed with 100 mL of ether and the ether layer separated. The organic extracts were combined, dried over magnesium sulfate, filtered and the volatiles removed by rotary evaporation to leave 13.7 g of oil (90 percent).
1H NMR (CDCl3): 7.08 (d, 1H), 6.90 (d, 1H), 2.44 (s, 3H). 13C{1H} NMR (CDCl3): 134.35, 130.15, 122.99, 109.65, 68.22, 31.88, 25.90, 14.83.
2-methyl-3-phenyl-thiophene A 500 mL flask was charged with 13.7 g (77 mmol) of 3-bromo-2-methyl-thiophene, 0.21 g (0.40 mmol) of NiCl2(dppp) and 250 mL of ether. The addition funnel was charged with 26 ml of phenyl magnesium bromide (77 mmol, 3.0 M in ether) and the Grignard slowly added to the thiophene solution over 1 hour with cooling in an ice bath was utilized to cool the reaction during the addition. After adding all the Grignard, the reaction was stirred at room temperature for 3 hours, cooled to 0° C. and quenched with 100 mL of 1 M HCl(aq). The organic layer was separated and the water solution extracted twice with 75 mL of diethyl ether. The organic extracts were combined, dried over magnesium sulfate, filtered and the volatiles removed in vacuo to leave 13.3 g (99 percent) of an orange oil.
1HNMR (CDCl3): 7.7-7.4 (m, 5H), 7.2 (m, 2H), 2.66 (s, 3H). 13C{1H} NMR(CDCl3): 139.06, 137.19, 134.50, 129.62, 129.08, 128.80, 127.57, 127.07, 121.94, 14.53.
5,6-dihydro-2,5-dimethyl-3-phenyl-4H-cyclopenta[b]thiophen-4-one A 500 mL three neck flask was charged with 8 g of phosphorus pentoxide (57 mmol) and 45 g of polyphosphoric acid (475 mmol). The system was fitted with a mechanical stirred, capped with an addition funnel, condensor and septa and purged with nitrogen. The system was heated to 150° C. until nearly all the phsophorus pentoxide dissolved in the viscous mixture (about 1.5 hours). Once nearly all solid had dissolved, the system was cooled to 70° C. and over 3 hours a 350 mL dichloromethane solution containing 8.3 g of 2-methyl-3-phenyl-thiophene (47.6 mmol) and 7 g of methacrylic acid (83 mmol) was added. After stirring for an additional 2 hours, another 4 g of methacrylic acid (46 mmol) was added followed 2 hours later by addition of another 4 g of methacyrlic acid (46 mmol). After stirring at 70° C. for 14 hrs, the mixture was cooled to 0° C. and 100 mL of ice water was added. After stirring for 1 hour, the organic layer was separated and the aqueous phase extracted twice with 75 mL of dichloromethane. The organic extracts were combined, concentrated and washed three times with 1.0 M NaOH solution The organic extracts were then dried over magnesium sulfate, filtered and the volatiles removed by rotary evaporation to leave 10.3 g of oil (89 percent).
1H NMR (CD2Cl2): 7.5-7.3 (m, 5H), 3.2 (d, 1H), 2.85 (d, 1H), 2.6-2.5 (m, 4H), 1.35-1.25 (d, 3H).
5,6-Dihydro-2,5-dimethyl-3-phenyl-4H-cyclopenta[b]thiophene-4-ol A 500 mL flask was charged with 9.9 g (41 mmol) of 5,6-dihydro-2,5-dimethyl-3-phenyl-4H-cyclopenta[b]thiophen-4-one followed by 200 mL of THF. After sparging with nitrogen and cooling to 0° C., a 20 mL 1.0 M solution of lithium aluminum hydride in ether (20.4 mmol) was added over 20 minutes. After the addition was complete, the reaction was allowed to warm to room temperature and stirred for 1.5 hours. The mixture was quenched with 200 mL of water and 150 mL of ether were added. The mixture was filtered to remove the solids and the organic layer was separated. The water layer was washed twice with 100 mL of ether and the extracts combined and dried over magnesium sulfate. The mixture was filtered and the volatiles removed by rotary evaporation to leave 10.3 g of oil (104 percent).
1H NMR (CD2Cl2): 7.8-7.2 (m, 5H), 4.95 (d, 0.4H), 4.82 (d, 0.6H), 3.1-2.6 (m, 4H), 2.6-2.2 (m, 3H), 1.2-1.35 (m, 3H). 13C{1H} NMR (CD2Cl2): 148.40, 146.66, 140.6, 139.70, 139.30, 136.20, 134.05, 129.08, 128.56, 126.91, 80.70, 74.24, 48.88, 43.77, 35.59, 35.37, 19.2, 15.13, 14.54.
2,5-dimethyl-3-phenyl-6H-cyclopenta[b]thiophene A 250 mL flask was charged 9.1 g (37 mmol) of 5,6-Dihydro-2,5-dimethyl-3-phenyl-4H-cyclopenta[b]thiophene-4-ol followed by 175 mg (0.9 mmol) of p-toluenesulfonic acid and 50 mL of benzene. The mixture was sparged with nitrogen and heated to 45° C. for 15 min—the reaction was then cooled and quenched by adding 150 mL of a ice cold saturated water/sodium bicarbonate mixture. The organic layer was separated, the extract dried over magnesium sulfate, filtered and the volatiles removed in vacuo. The compound was dissolved in hexanes and purified by column chromatography to give 4.2 g of the desired material (50 percent).
1H NMR (CD2Cl2): 7.55-7.25 (m, 5H), 6.44/6.35 (2 s, 1H), 3.14 (s, 2H), 2.5 (m, 3H), 2.15 (s, 3H). 13C{1H} NMR (CD2Cl2): 145.72, 145.65, 140.72, 136.76, 133.42, 129.22, 128.85, 126.92, 126.76, 122.08, 121.79, 40.61, 16.88, 14.84, 14.18.
2,5-dimethyl-3-phenyl-cyclopenta[b]thiophene(-1)lithium A 125 mL jar was charged with 3.29 g (14.5 mmol) of 2,5-dimethyl-3-phenyl-6H-cyclopenta[b]thiophene and 75 mL of hexanes. To this was added over five minutes 9.7 mL of nBuLi in hexanes (15.3 mmol, 1.6 M). The mixture was stirred at room temperature for several days and the obtained precipitate was filtered and washed twice with 25 mL of hexanes. The solid was dried in vacuo for two hours to leave 3.1 of solid (92 percent).
N-(1,1-dimethylethyl)-1-(2,5-dimethyl-3-phenyl-4H-cyclopenta[b]thien-4-yl)-1,1-dimethylsilanamine A 125 mL flask was charged with 1.12 g (4.8 mmol) of 2,5-dimethyl-3-phenyl-cyclopenta[b]thiophene(1)lithium and to this added 25 mL of THF. To this solution was added a 5 mL THF solution containing 0.95 g (5.8 mmol) of N-(tert-butyl)-1,1-dimethyl-1-(chloromethyl)silanamine. The mixture was stirred at room temperature for 3 hours and the volatiles removed in vacuo. The residue was extracted into 40 mL of hexanes, filtered and the volatiles removed in vacuo to leave 1.62 g of yellow oil, 94 percent.
1H NMR (C6D6): 7.47 (d, 2H), 7.26-7.1 (m, 3H), 6.52 (s, 1H), 3.29 (s, 1H), 2.37 (s, 3H), 2.09 (s, 3H), 1.10 (s, 9H), 0.09 (s, 3H), 0.04 (s, 3H). 13C{1H} NMR (C6D6): 149.00, 146.59, 137.67, 137.23, 134.87, 129.55, 128.55, 126.54, 122.48, 50.86, 33.69, 18.04, 14.69, −0.61, −1.56.
[1-[(3a,4,5,6,6a-η)-2,5-dimethyl-3-phenyl-4H-cyclopenta[b]thien-6-yl)-N-(1,1-dimethylethyl)-1,1-dimethylsilanamato(2-)-κN]bis(N,N-dimethylamino titanium) A 90 mL flask was charged with 1.51 g of N-(1,1-dimethylethyl)-1-(2,5-dimethyl-3-phenyl-4H-cyclopenta[b]thien-4-yl)-1,1-dimethylsilanamine, 990 mg of Ti(NMe2)4 and 40 mL of octane. The mixture was heated to reflux for 11 hrs at which time there was nearly complete conversion of the starting material to the crude diamide complex.
1HNMR (C6D6): 7.40 (d, 2H), 7.27 (t, 2H), 7.10 (m, 1H), 2.97 (s, 6H, NMe2), 2.72 (s, 6H, NMe2), 5.93 (s, 1H), 2.12 (s, 3H), 2.08 (s, 3H), 1.30 (s, 9H), 0.77 (s, 3H), 0.58 (s, 3H).
[1-[(3a,4,5,6,6a-η)-2,5-dimethyl-3-phenyl-4H-cyclopenta[b]thien-6-yl)-N-(1,1-dimethylethyl)-1,1-dimethylsilanamato(2-)-κN]dichloro titanium)
The reaction mixture of example 3 was diluted with 20 mL of toluene and to this added 15 mL of chlorotrimethylsilane. After 6 hours, the volatiles were removed in vacuo and the residue extracted into toluene, filtered and the volatiles removed in vacuo. To the residue was added 10 mL of hexanes and after stirring for 10 minutes, the suspension was concentrated to about 6 mL and cooled to −30° C. overnight. The mother liquor was decanted, the solid washed twice with 5 mL of cold hexanes and the solid dried in vacuo (1st crop: 220 mg). The hexanes mother liquor was concentrated to about 3 mL and cooled to −30° C. to give a second crop of 680 mg of material. The hexanes mother liquor was concentrated to dryness and the residue triturated with 3 mL of hexanes and the suspension cooled to −30° C. to give a 3rd crop of 140 mg. The NMR spectra of all three crops are essentially identical: total yield 1.04 g, 51 percent
1H NMR (C6D6): 7.49 (d, 2H), 7.24-7.15 (m, 3H), 6.59 (s, 1H), 2.13 (s, 3H), 2.07 (s, 3H), 1.39 (s, 9H), 0.63 (s, 3H), 0.40 (s, 3H). 13C{1H} NMR (C6D6): 147.06, 146.68, 144.97, 139.66, 134.51, 130.45, 129.89, 129.14, 128.80, 117.65, 117.36, 62.01, 32.33, 19.79, 15.11, 3.40, 3.18.
[1-[(3a,4,5,6,6a-η)-2,5-dimethyl-3-phenyl-4H-cyclopenta[b]thien-6-yl)-N-(1,1-dimethylethyl)-1,1-dimethylsilanamato(2-)-κN]dimethyl titanium) A 90 mL jar was charged with 0.14 g (0.30 mmol) of [1-[(3a,4,5,6,6a-η)-2,5-dimethyl-3-phenyl-4H-cyclopenta[b]thien-6-yl)-N-(1,1-dimethylethyl)-1,1-dimethylsilanamato(2-)-κN]bis(N,N-dichloro titanium). To this was added 20 mL of ether and the solution cooled to −30° C. To this was added 0.3 mL (0.9 mmol, 3.0 M) of methyl magnesium bromide and after 40 minutes, the volatiles were removed and the material extracted into 20 mL of hexanes. After 10 minutes of stirring, the suspension was filtered and the filtrate concentrated to dryness. The solid was again extracted into 10 mL of hexanes, filtered and the filtrate concentrated to dryness to leave 118 mg (0.30 mmol, 92 percent) of yellow solid.
1H NMR (C6D6): 7.47 (d, 2H), 7.25 (t, 2H), 7.13 (m, 1H), 6.72 (s, 1H), 2.19 (s, 3), 1.92 (s, 3), 1.54 (s, 9H), 0.79 (s, 3H), 0.57 (s, 3H), 0.42 (s, 31), 0.39 (s, 3H). 13C{1H} NMR (C6D6): 141.97, 141.04, 139.56, 135.78, 135.64, 129.97, 128.91, 128.88, 112.94, 57.74, 57.05, 50.93, 34.36, 18.39, 14.89, 4.36, 4.01.
Polymerization General Conditions
Mixed alkanes and liquid olefins are purified by sparging with purified nitrogen followed by passage through columns containing alumina (A-2, available from LaRoche Inc.) and Q5 reactant (available from Englehard Chemicals Inc.) at 50 psig (450 kPa) using a purified nitrogen pad. All transfers of solvents and solutions described below are accomplished using a gaseous pad of dry, purified nitrogen or argon. Gaseous feeds to the reactor are purified by passage through columns of A-204 alumina (available from LaRoche Inc.) and Q5 reactant. The aluminas are previously activated by treatment at 375° C. with nitrogen, and Q5 reactant is activated by treatment at 200° C. with 5 percent hydrogen in nitrogen.
Polymerization 1
A stirred, two-liter Parr reactor was charged with 740 g of mixed alkanes (Isopar E™) and with 118 g of purified 1-octene comonomer. Hydrogen (25 psi (170 kPa), 5.7 mmoles) was added as a molecular weight control agent by differential pressure expansion from a 75 mL addition tank at 300 psig (2.2 MPa). The reactor was heated to 140° C. and saturated with ethylene at 500 psig (3.5 MPa). Catalyst and methyldi(C14-18 alkyl)ammonium tetrakis(pentafluorophenyl)borate (MDPB) or trispentafluorophenylborane (FAB) cocatalyst as 0.005M solutions in toluene were premixed in a glovebox and transferred to a catalyst addition tank and injected into the reactor. The polymerization conditions were maintained during the run with ethylene on demand.
After 15 minute reaction time, the resulting solution was removed from the reactor into a nitrogen purged collection vessel containing 100 ml of isopropyl alcohol and 20 ml of a 10 weight percent toluene solution of hindered phenol antioxidant (Irganox™ 1010 from Ciba Geigy Corporation) and phosphorus stabilizer (Irgafos™ 168 from Ciba Geigy Corporation). Polymers formed are dried in a programmed vacuum oven with a maximum temperature of 145° C. and a 20 hour heating period. The results are contained in Table 1.
*comparative, not an example of the invention
1(dimethyl(N-tert-butyl)-1,1-dimethyl-1-((1,2,3,3a,8a-η)-1,5,6,7-tetrahydro-2-methyl-s-indacen-1-yl)-silananiinato(2-)-κN)-titanium) prepared as outlined in WO98/27103
2melt index as determined by micromelt technique
For purposes of United States patent practice, this application claims the benefit of U.S. Provisional Application No. 60/364,809, filed Mar. 14, 2002.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US03/06316 | 3/3/2003 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 60364809 | Mar 2002 | US |
