Claims
- 1. A catalyst component useful in combination with a dialkyl aluminum halide cocatalyst in propylene polymerization, said catalyst component being substantially free of extraneous halide and prepared by a method consisting essentially of the step of reacting reactants consisting essentially of unmilled TiCl.sub.3 which is substantially free of extraneous halide and an electron donor compound dissolved in a liquid alkane or cycloalkane solvent containing substantially no olefin in which said TiCl.sub.3 is dispersed without a milling step whereby said TiCl.sub.3 is modified, said electron donor being selected from the group consisting of:
- (a) organic acid esters of the general formula
- wherein R.sub.1 is an alkyl group of 1 to 16 carbon atoms, inclusive;
- (b) hindered phenolic compounds of the general formula ##STR3## wherein R.sup.2 is an alkyl group of 1 to 6 carbon atoms, inclusive; R.sup.3 is hydrogen or an alkyl group of 1 to 6 carbon atoms inclusive; and R.sup.4 is an alkyl group of 2 to 24 carbon atoms, inclusive; and
- (c) silyl esters of the general formula
- R.sub.n.sup.5 Si(OR.sup.6).sub.4-n
- wherein R.sup.5 and R.sup.6 can be the same or different and are alkyl groups of 1 to 8 carbon atoms, inclusive, or aryl groups, and n=1 or 2.
- 2. The catalyst component of claim 1 wherein said TiCl.sub.3 is substantially pure.
- 3. The catalyst component of claim 1 wherein the reaction between said TiCl.sub.3 and said electron donor compound is carried out at a temperature of about 0.degree. to 100.degree. C.
- 4. The catalyst component of claim 3 wherein said reaction is carried out at ambient temperature.
- 5. The catalyst component of claim 1 wherein the molar ratio of said electron donor compound to said TiCl.sub.3 is in the range of about 0.05 to 5:1.
- 6. The catalyst component of claim 1 wherein said electron donor compound is an organic acid ester of (a) selected from the group consisting of ethyl benzoate, propyl benzoate and butyl benzoate.
- 7. The catalyst component of claim 1 wherein said electron donor compound is a hindered phenolic compound of (b) comprising n-octadecyl-4-hydroxy-3,5-ditertbutyl phenyl propionate.
- 8. The catalyst component of claim 1 wherein said electron donor compound is a silyl ester of (c) comprising isobutyl trimethoxy silane.
- 9. The catalyst component of claim 1 wherein said solvent has 4 to 20 carbon atoms, inclusive.
- 10. The catalyst component of claim 1 wherein said TiCl.sub.3 is in the form of substantially spherical particles.
- 11. A catalyst system comprising the catalyst component of claim 1 in combination with a cocatalyst comprising a compound of the formula R.sub.2.sup.7 AlX where R.sup.7 is an alkyl group of 1 to 20 carbon atoms, inclusive and X is a halogen atom.
- 12. The catalyst system of claim 11 wherein R.sup.7 is an alkyl group of 2 to 4 carbon atoms, inclusive.
- 13. The catalyst system of claim 11 wherein X is chlorine.
- 14. The catalyst system of claim 11 wherein the molar ratio of said cocatalyst compound to said TiCl.sub.3 is in the range of about 1 to 50:1.
- 15. The catalyst system of claim 14 wherein said molar ratio is about 3.5 to 12:1.
- 16. The catalyst system of claim 11 wherein said cocatalyst comprises diethylaluminum chloride.
- 17. The catalyst system claim 11 wherein said cocatalyst compound is mixed with a trialkyl aluminum compound.
- 18. The catalyst system of claim 11 wherein said cocatalyst compound is mixed with a phenolic compound.
- 19. A method of preparing a catalyst component useful in combination with a dialkyl aluminum halide catalyst in propylene polymerization, said method consisting essentially of the step of reacting reactants consisting essentially of unmilled TiCl.sub.3 and an electron donor compound dissolved in a liquid alkane or cycloalkane solvent in which said TiCl.sub.3 is dispersed without a milling step whereby said TiCl.sub.3 is modified, said reactants being substantially free of extraneous halide, said electron donor compound being selected from the group consisting of:
- (a) organic acid esters of the general formula
- wherein R.sup.1 is an alkyl group of 1 to 16 carbon atoms, inclusive;
- (b) hindered phenolic compounds of the general formula
- wherein R.sup.2 is an alkyl group of 1 to 6 carbon atoms, inclusive; R.sup.3 is hydrogen or an alkyl group of 1 to 6 carbon atoms, inclusive; and r.sup.4 is an alkyl group of 2 ro 24 carbon atoms, inclusive; and
- (c) silyl esters of the general formula
- R.sub.n.sup.5 Si(OR.sup.6).sub.4-n
- wherein R.sup.5 and R.sup.6 can be the same or different and are alkyl groups of 1 to 8 carbon atoms, inclusive, or aryl groups, and n=1 or 2.
- 20. The method of claim 19 wherein said TiCl.sub.3 is substantially pure.
- 21. The method of claim 19 wherein the reaction between said TiCl.sub.3 and said electron donor compound is carried out at a temperature of about 0.degree. to 100.degree. C.
- 22. The method of claim 21 wherein said reaction is carried out at ambient temperature.
- 23. The method of claim 19 wherein the molar ratio of said electron donor compound to said TiCl.sub.3 is in the range of about 0.05 to 5:1.
- 24. The method of claim 19 wherein said electron donor compound is an organic acid ester of (a) selected from the group consisting of ethyl benzoate, propyl benzoate and butyl benzoate.
- 25. The method of claim 19 wherein said electron donor compound is a hindered phenolic compound of (b) comprising n-octadecyl-4-hydroxy-3,5-ditertbutyl phenyl propionate.
- 26. The method of claim 19 wherein said electron donor compound is a silyl ester of (c) comprising isobutyl trimethoxy silane.
- 27. The method of claim 19 wherein said solvent has 4 to 20 carbon atoms, inclusive.
- 28. The method of claim 19 wherein said TiCl.sub.3 is in the form of substantially spherical particles.
- 29. The catalyst component of claim 9 wherein said solvent is heptane.
- 30. The method of claim 27 wherein said solvent is heptane.
Parent Case Info
This application is a continuation, of application Ser. No. 07/71,978, filed Jul. 10, 1987 and now abandoned.
US Referenced Citations (47)
Continuations (1)
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71978 |
Jul 1987 |
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