Title of Invention

BRIDGED METALLOCENE COMPOUND, OLEFIN POLYMERIZATION CATALYST CONTAINING THE SAME, AND ETHYLENE POLYMER OBTAINED WITH THE CATALYST

Abstract It relates to a metallocene compound useful as an olefin polymerization catalyst or catalyst component, and an olefin polymerization method using an olefin polymerization catalyst containing the metallocene compound. More particularly, it relates to an olefin polymerization catalyst capable of producing an olefin polymer having a high melt tension, excellent mechanical strength and excellent particle properties with a high polymerization activity, an olefin polymerization method using this catalyst, an ethylene polymer which is obtained by the polymerization method and is excellent in moldability, easy openability, and particularly excellent in mechanical strength as compared with conventionally known ethylene polymers, and a thermoplastic resin composition containing the ethylene polymer. More particularly, it provides a molded article and a film formed from the ethylene polymer or the thermoplastic resin composition containing the ethylene polymer, and a laminate film comprising the film. It provides an olefin polymer which shows little neck-in in T-die molding, does not cause take-off surging, is particularly excellent in mechanical strength, and has a large number of long-chain branches caused by simultaneously inducing production of a macromonomer as a source of long-chain branches and repolymerization of the produced macromonomer in the coexistence of a single type or plural types of bridged metallocene compounds including a group derived from a cyclopentadienyl group having a different structure in the same polymerization system, an olefin polymerization catalyst and a polymerization method capable of efficiently producing the olefin polymer.
Full Text FIELD OF THE INVENTION [0001]
The present invention relates to metallocene compounds useful as olefin polymerization catalysts or catalyst components, and to olefin polymerization processes with an olefin polymerization catalyst containing the metallocene compound. In detail, the invention relates to olefin polymerization catalysts that can catalyze with high polymerization activity the production of olefin polymers having high melt tension, excellent mechanical strength and good particle properties, and relates to olefin polymerization processes using the catalysts. Further, the invention relates to ethylene polymers obtained by the polymerization processes that have good processability and particularly excellent mechanical strength compared to conventional ethylene polymers, and relates to thermoplastic resin compositions containing the ethylene polymers. In more detail, the invention is concerned with shaped articles ical strength compaor films that are obtained from the ethylene polymers or the thermoplastic resin compositions containing the ethylene polymers, or relates to laminate films including the films. Furthermore, the invention is concerned with ethylene polymers that have good processability and easy-opening properties compared to conventional ethylene polymers, and thermoplastic resin
compositions containing the ethylene polymers . In more detail, the invention is concerned with shaped articles or films that are obtained from the ethylene polymers or the thermoplastic resin compositions containing the ethylene polymers, or relates to laminate films including the films.
BACKGROUND OF THE INVENTION
[0002]
Olefin polymers are shaped by various methods and used in wide-ranged applications. For example, ethylene polymers are extruded into films or sheets for use in the packaging of foods, liquids or daily sundries. Olefin polymers require various properties depending on the shaping methods or use applications. In the case of T-die extrusion as an example, they require performances such as stable processability even at high speed (high-speed film-forming properties) and small neck-in.
[0003]
Low density polyethylenes (LDPE) by high-pressure radical polymerization have a high melt tension because of their complicated long-chain branched structures, and show good shaping processability such as small neck-in, thereby finding various uses. However, shaped articles therefrom still have low mechanical strength properties such as tensile strength,
tear strength and impact resistant strength. Further, these polymers show poor high-speed film-forming properties in T-die extrusion. [0004]
In contrast to LDPE, Ziegler-catalyzed or metallocene-catalyzed ethylene polymers possess high tensile strength, tear strength and impact resistant strength due to their molecular structures, and they are used in applications requiring mechanical strength. However, these polymers have a low melt tension and consequent poor shaping processability. [0005]
To solve these problems, [1] LDPE is blended with a Ziegler-catalyzed or metallocene-catalyzed ethylene polymer (Patent Document 1); [2] the molecular weight distribution is broadened by multistage polymerization (Patent Document 2); [3] a long-chain branched ethylene polymer is produced with a chromium catalyst; [4] a long-chain branched ethylene polymer is produced with a specific metallocene catalyst (Patent Document 3) ; [5] macro monomers are copolymerized with use of a specific metallocene catalyst to give a long-chain branched ethylene polymer (Patent Document 4) ; or [6] ethylene and diene are copolymerized with use of a specific metallocene catalyst to afford a long-chain branched ethylene polymer (Patent Documents 6 and 7). However, the method [1] greatly increases
costs in the blending of the polymers, and the ethylene polymers obtained by the methods [2], [3], [4] and [5] have a small number of long-chain branches and do not have a sufficient melt tension or shaping processability. Further, the method [6] can deteriorate mechanical characteristics inherent to polymers or can result in gelation when the diene is used in large amounts. [0006]
Patent Documents 8 and 9 teach the use of two or more kinds of metallocene compounds or organometallic complexes in order to produce more long-chain branches or to increase the melt tension. However, the number of long-chain branches is still insufficient and problems remain in terms of shaping processability. Further, the catalytic activity is far below the industrial level. [0007]
As discussed above, it has been difficult to produce resins having high melt tension and excellent mechanical strength inexpensively and efficiently by means of the conventional catalyst systems or by blending resins. In other words, the development of efficient production processes for ethylene polymers having high melt tension and excellent mechanical strength is important and highly valuable in the industrial production.
[0008]
When ethylene polymers are used as sealants in packaging materials, the polymers require mechanical strength such as heat seal strength or pack breakage strength to protect the contents. However, packaging materials that are easily opened (have easy openability) attract attention out of consideration for elderly people, infants and disabled people. One of the approaches for easy openability is to appropriately weaken the heat seal strength at the sealed portion. Accordingly, there is a need for ethylene polymers having appropriately low heat seal strength. [0009]
The present inventors studied diligently in view of the problems in the art as describe above. They have then found that a single or plural kinds of bridged metallocene compounds having differing cyclopentadienyl-derived groups can afford macromonomers that are a source of long-chain branches and can simultaneously catalyze the repolymerization of the macromonomers into olefin polymers having a large number of long-chain branches, small neck-in in the T-die extrusion, small take-up surge and superior mechanical strength or olefin polymers having small neck-in in the T-die extrusion, small take-up surge and easy opening properties. Such compounds as olefin polymerization catalysts and polymerization processes using the compounds have been found to be capable of efficiently producing the olefin polymers as described above. The present invention has been completed based on the findings.
Patent Document 1: WO 99/046325
Patent Document 2: JP-A-H02-53811
Patent Document 3: JP-A-H04-213306
Patent Document 4: JP-A-H08-502303
Patent Document 5: JP-A-H04-213306
Patent Document 6: JP-A-H09-227626
Patent Document 7: JP-A-H04-506372
Patent Document 8: JP-A-H07-252311
Patent Document 9: JP-A-2006-2057
SUMMARY OF THE INVENTION [0010]
The present invention has been made in view of the background art as discussed above. It is therefore an object of the invention to provide bridged metallocene compounds for olefin polymerization that can afford with high polymerization activity a relatively low molecular weight olefin polymer (macromonomer) having a higher proportion of terminal double bonds than produced by conventional metallocene compounds. It is another object to provide olefin polymerization catalysts
containing the bridged metallocene compounds, in detail olefin polymerization catalysts that can catalyze with high polymerization activity the production of olefin polymers having high melt tension, excellent mechanical strength and good particle properties, and to provide polymerization processes using the catalysts. It is a further object of the invention to provide ethylene homopolymers or copolymers that have good processability and particularly excellent mechanical strength compared to conventional ethylene polymers, and to provide thermoplastic resin compositions containing the polymers. It is a still further object to provide shaped articles or films that are obtained from the polymers or the thermoplastic resin compositions, or to provide laminate films including the films. Furthermore, the invention has an object of providing ethylene homopolymers or copolymers that have good processability and easy-opening properties compared to conventional ethylene polymers, and thermoplastic resin compositions containing the ethylene polymers. It is a still further object of the invention to provide shaped articles or films that are obtained from the polymers or the thermoplastic resin compositions, or to provide laminate films including the films. [0011]
A bridged metallocene compound according to the present
invention is represented by Formula [1] below: [0012]
(Formula Removed)
[0013]
wherein R1, R2, R3 and R4 are selected from a hydrogen atom, hydrocarbon groups, silicon-containing groups, heteroatom-containing groups and halogen-containing groups and are the same or different from one another; R1, R2, R3 and R4 are not all hydrogen atoms and at least one of these groups is an ethyl group or a group represented by any of Formulae [2] to [7] below; neighboring substituent groups among R1 to R4 may be linked together to form an aliphatic ring; Q1 is selected from Cl-20 hydrocarbon groups, halogen-containing groups, silicon-containing groups, germanium-containing groups and tin-containing groups; X independently at each occurrence is a group selected from a hydrogen atom, halogen atoms, hydrocarbon groups, halogen-containing groups, silicon-containing groups, oxygen-containing groups,
sulfur-containing groups, nitrogen-containing groups and phosphorus-containing groups; and M is a titanium atom, a zirconium atom or a hafnium atom; [0014]
(Formula Removed)
[0015]
(Formula Removed)
[0016]
(Formula Removed)
[0018]
(Formula Removed)
[0019]
(Formula Removed)
[0020]
wherein R7 to R16 are selected from a hydrogen atom, hydrocarbon groups, silicon-containing groups, heteroatom-containing groups and halogen-containing groups and are the same or different from one another, but they are not aryl groups; D and E are each a divalent heteroatom; G and L are each a trivalent heteroatom; and T and W are each a tetravalent heteroatom or a carbon atom.
An olefin polymerization catalyst (a) according to the present invention comprises the following components (A) and (C) : [0021]
Component (A): the bridged metallocene compound represented by Formula (1) above;
[0022]
Component (C): at least one compound selected from the group consisting of:
(c-1) organometallic compounds represented by Formulae [11], [12] and [13] below;
(c-2) organoaluminum oxy-compounds; and
(c-3) compounds that react with the component (A) to form an ion pair; [0023]
(Formula Removed)
[0024]
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; X is a halogen atom;
0 (Formula Removed)
[0026]
wherein Ma is Li, Na or K; and Ra is a Cl-15 hydrocarbon group; [0027]
(Formula Removed)
[0028]
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; Mb is selected from
Mg, Zn and Cd; X is a halogen atom; 0 An olefin polymerization catalyst (b) according to the present invention comprises the following components (A), (B) and (C): [0029]
Component (A): the bridged metallocene compound represented by Formula [1] above; [0030]
Component (B): a bridged metallocene compound represented by Formula (14) below; [0031]
(Formula Removed)
[0032]
wherein R17 to R20, and R21 to R28 are selected from a hydrogen atom, hydrocarbon groups, halogen-containing groups, oxygen-containing groups, nitrogen-containing groups, boron-containing groups, sulfur-containing groups, phosphorus-containing groups, silicon-containing groups, germanium-containing groups and tin-containing groups and are the same or different from one another; neighboring substituent groups among these groups may be linked together to form a ring; Q2 is selected from Cl-20 hydrocarbon groups, halogen-containing groups, silicon-containing groups, germanium-containing groups and tin-containing groups; M is selected from a titanium atom, a zirconium atom and a hafnium atom; and X independently at each occurrence is a group selected from a hydrogen atom, halogen atoms, hydrocarbon groups, halogen-containing groups, silicon-containing groups, oxygen-containing groups, sulfur-containing groups, nitrogen-containing groups and phosphorus-containing groups;
Component (C): at least one compound selected from the group consisting of:
(c-1) organometallic compounds represented by Formulae [18], [19] and [20] below;
(c-2) organoaluminum oxy-compounds; and
(c-4) compounds that react with the components (A) and (B) to form an ion pair;
[0033]
(Formula Removed)
[0034]
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; X is a halogen atom;
0 (Formula Removed)
[0036]
wherein Ma is Li, Na or K; and Ra is a Cl-15 hydrocarbon group; [0037]
(Formula Removed)
[0038]
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; Mb is selected from Mg, Zn and Cd; X is a halogen atom; 0 The olefin polymerization catalyst (b) may further contain a solid carrier (S). In an embodiment, such olefin polymerization catalyst may comprise a solid catalyst
component (Kl) comprising the solid carrier (S) , the component (C) and the component (A), and a solid catalyst component (K2) comprising the solid carrier (S), the component (C) and the component (B). In another embodiment, such olefin polymerization catalyst may comprise a solid catalyst component (K3) comprising the solid carrier (S) , the component (A), the component (B) and the component (C). [0039]
In Formula (1) , at least one of R1, R2, R3 and R4 is preferably a hydrocarbon group. The component (C) is preferably an organoaluminum oxy-compound. The solid carrier (S) is preferably a porous oxide. [0040]
A process for producing ethylene polymers according to the present invention comprises homopolymerizing ethylene or polymerizing ethylene and a C3-20 olefin in the presence of any of the olefin polymerization catalysts described above. [0041]
An ethylene polymer (i) according to the present invention is obtained by homopolymerizing ethylene or
copolymerizing ethylene and a C4-10 a-olefin in the presence of the olefin polymerization catalyst (b) and satisfies the following requirements [1] to [5] at the same time:
[1] the melt flow rate (MFR) as measured at 190°C under
a load of 2.16 kg is in the range of 0.1 to 100 g/10 min;
[2] the density (d) is in the range of 875 to 970 kg/m3;
[3] the ratio [MT/* (g/P) ] is in the range of 1.50 x 10-4 to 9.00 x 10-4 wherein [MT (g)] is the melt tension at 190°C and [* (P) ] is the shear viscosity at 200°C and an angular velocity of 1.0 rad/sec;
[4] per 1000 carbon atoms, the total of methyl branches [A (/1000 C) ] and ethyl branches [B (/1000 C) ] , [ (A + B) (/1000 C) ] , is not more than 1.8 according to 13C-NMR;
[5] the zero-shear viscosity at 200°C [o (P)] and the weight average molecular weight (Mw) measured by GPC-viscometry (GPC-VISCO) satisfy Equation (Eq-1) below: [0042]
(Formula Removed)
[0043]
An ethylene polymer (ii) according to the present invention is obtained by homopolymerizing ethylene or
copolymerizing ethylene and a C4-10 α-olefin in the presence of the olefin polymerization catalyst (b) and satisfies the following requirements [1] to [6] at the same time:
[1] the melt flow rate (MFR) as measured at 190°C under a load of 2.16 kg is in the range of 0.1 to 100 g/10 min;
[2] the density (d) is in the range of 875 to 970 kg/m3;
[3] the ratio [MT/ (g/P) ] is in the range of 2.50 x 10-4 to 9.00 x 10-4 wherein [MT (g)] is the melt tension at 190°C and [* (P)] is the shear viscosity at 200°C and an angular velocity of 1.0 rad/sec;
[4] per 1000 carbon atoms, the total of methyl branches [A (/1000 C) ] and ethyl branches [B (/1000 C) ] , [ (A + B) (/1000 C)], is not more than 1.8 according to 13C-NMR;
[5] the zero-shear viscosity at 200°C [0 (P)] and the weight average molecular weight (Mw) measured by GPC-viscometry (GPC-VISCO) satisfy Equation (Eq-1) below: [0044]
(Formula Removed)
[0045]
[6] a molecular weight distribution curve obtained by GPC shows a molecular weight at a maximum weight fraction (peak top M) in the range of 1.0 x 104.30 to 1.0 x 104.50. [0046]
An ethylene polymer (iii) according to the present invention is obtained by homopolymerizing ethylene or
copolymerizing ethylene and a C4-10 α-olefin in the presence of the olefin polymerization catalyst (b) and satisfies the following requirements [1] to [6] at the same time:
[1] the melt flow rate (MFR) as measured at 190°C under
a load of 2.16 kg is in the range of 0.1 to 100 g/10 min;
[2] the density (d) is in the range of 875 to 936 kg/m3;
[3] the ratio [MT/V (g/P) ] is in the range of 2.50 x 10"4 to 9.00 x 10~4 wherein [MT (g)] is the melt tension at 190°C and [* (P)] is the shear viscosity at 200°C and an angular velocity of 1.0 rad/sec;
[4] per 1000 carbon atoms, the total of methyl branches [A (/1000 C) ] and ethyl branches [B (/1000 C) ] , [ (A + B) (/1000 C) ] , is not more than 1.8 according to 13C-NMR;
[5] the zero-shear viscosity at 200°C [0 (P)] and the weight average molecular weight (Mw) measured by GPC-viscometry (GPC-VISCO) satisfy Equation (Eq-1) below: [0047]
(Formula Removed)
[0048]
[6] a molecular weight distribution curve obtained by GPC shows a molecular weight at a maximum weight fraction (peak top M) in the range of 1.0 x 104.20 to 1.0 x 104.50. [0049]
An ethylene polymer (iv) according to the present invention is obtained by homopolymerizing ethylene or
copolymerizing ethylene and a C3-10 α-olefin in the presence of the olefin polymerization catalyst (b) and satisfies the
following requirements [1] to [5] at the same time:
[1] the ratio [M3-4/M3-10] is in the range of 0.30 to 1.00 wherein [M3-4 (mol%) ] is the content of C3-4 α-olefins and [M3-10 (mol%)] is the content of C3-10 a-olefins according to 13C-NMR;
[2] the melt flow rate (MFR) as measured at 190°C under a load of 2.16 kg is in the range of 0.1 to 100 g/10 min;
[3] the density (d) is in the range of 875 to 970 kg/m3;
[4] the ratio [MT/ (g/P) ] is in the range of 1.50 x 10~4 to 9.00 x 10~4 wherein [MT (g)] is the melt tension at 190°C and [* (P) ] is the shear viscosity at 200°C and an angular velocity of 1.0 rad/sec;
[5] the zero-shear viscosity at 200°C [0 (P)] and the weight average molecular weight (Mw) measured by GPC-viscometry (GPC-VISCO) satisfy Equation (Eq-1) below: [0050]
(Formula Removed)
[0051]
The ethylene polymers (i to iii) may be blended with other thermoplastic resins to give thermoplastic resin compositions having excellent processability and superior mechanical strength. The ethylene polymers (i to iii) and the resin compositions containing the ethylene polymers (i to iii) may be processed with good processability into shaped articles
having excellent mechanical strength, which are preferably films, and more preferably laminate films containing the films. [0052]
The ethylene polymers (iv) may be blended with other thermoplastic resins to give thermoplastic resin compositions having excellent processability and easy opening properties. The ethylene polymers (iv) and the resin compositions containing the ethylene polymers (iv) may be processed with good processability into shaped articles having easy opening properties, which are preferably films, and more preferably laminate films containing the films.
ADVANTAGEOUS EFFECTS OF THE INVENTION [0053]
The olefin polymerization catalysts (a) containing the bridged metallocene compound of the invention can catalyze olefin homopolymerization or copolymerization to provide low molecular weight olefin homopolymers or copolymers having an increased number of terminal double bonds. [0054]
According to the present invention, macromonomers can be produced efficiently by polymerizing one or more monomers selected from ethylene and α-olefins wherein at least one of the monomers is ethylene or propylene, in the presence of the
olefin polymerization catalyst (a) containing the bridged metallocene compound. [0055]
The olefin polymerization catalysts (b) containing the bridged metallocene compound of the invention can catalyze olefin homopolymerization or copolymerization to provide ethylene polymers having excellent shaping processability and a large number of long-chain branches. The processes of the invention can efficiently produce such polymers. [0056]
The ethylene polymers (i to iii) and the thermoplastic resin compositions containing the polymers can favorably give shaped articles, films or laminate films containing the films which have small neck-in in the T-die extrusion, small take-up surge and superior mechanical strength. The ethylene polymers (iv) and the thermoplastic resin compositions containing the polymers show excellent processability and can favorably give shaped articles, films or laminate films containing the films which have easy opening properties.
BRIEF DESCRIPTION OF THE DRAWINGS [0057]
Fig. 1 is a GPC chart of a polymer obtained in Example M-l.
Fig. 2 is a GPC chart of a polymer obtained in Example M-4.
Fig. 3 is a GPC chart of a polymer obtained in Example M-5.
Fig. 4 is a GPC chart of a polymer obtained in Example M-6.
Fig. 5 is a GPC chart of a polymer obtained in Example M-7.
Fig. 6 is a GPC chart of a polymer obtained in Example M-9.
PREFERRED EMBODIMENTS FOR CARRYING OUT THE INVENTION [0058]
There will be described in detail hereinbelow the bridged metallocene compounds of Formula [1], the olefin polymerization catalysts (a) containing the bridged metallocene compounds, the olefin polymerization catalysts (b) containing the bridged metallocene compounds of Formula [1] and the bridged metallocene compounds of Formula [14], the olefin polymerization processes using the olefin polymerization catalysts (a) or (b) , and the ethylene polymers (i to iv) obtained by homopolymerizing or copolymerizing ethylene in the presence of the olefin polymerization catalysts (b) .
[0059]
In the invention, the term polymerization comprehends not only homopolymerization but copolymerization, and the term polymer comprehends not only homopolymer but copolymer. [0060] Bridged metallocene compounds
Bridged metallocene compounds of the invention are represented by Formula [1] below: [0061]
(Formula Removed)
[0062]
In Formula [1], M is a Group IV transition metal atom in the periodic table, specifically titanium, zirconium or hafnium, and preferably zirconium. [0063]
In Formula [1], R1, R2, R3 and R4 are selected from a hydrogen atom, hydrocarbon groups, silicon-containing groups, heteroatom-containing groups and halogen-containing groups
and are the same or different from one another; R1, R2, R3 and R4 are not all hydrogen atoms and at least one of these groups is an ethyl group or a group represented by any of Formulae
[2] to [7] below; and neighboring substituent groups among R1 to R4 may be linked together to form an aliphatic ring.
[0064]
Examples of the hydrocarbon groups include Cl-20 alkyl groups, C3-20 cycloalkyl groups and C7-20 aralkyl groups (for example, benzyl group) . Specific examples include methyl group, ethyl group, n-propyl group, isopropyl group, allyl group, n-butyl group, t-butyl group, amyl group, n-pentyl group, n-hexyl group, n-heptyl group, n-octyl group, n-nonyl group, n-decanyl group, 3-methylpentyl group, 1,1-diethylpropyl group, 1,1-dimethylbutyl group, 1-methyl-l-propylbutyl group, 1,1-propylbutyl group, 1,l-dimethyl-2-methylpropyl group, l-methyl-l-isopropyl-2-methylpropyl group, cyclopentyl group, cyclohexyl group, cycloheptyl group, cyclooctyl group, norbornyl group, adamantyl group and benzyl group.
[0065]
Examples of the silicon-containing groups include hydrocarbon-substituted silyl groups such as trimethylsilyl group, triethylsilyl group, diphenylmethylsilyl group and dimethylphenylsilyl group.
[0066]
Examples of the heteroatom-containing groups include alkoxy groups, aryloxy groups and amino groups such as methoxy group, ethoxy group, phenoxy group, N-methylamino group, N,N-dimethylamino group and N-phenylamino group. [0067]
Examples of the halogen-containing groups include halogen atoms and halogen-substituted alkyl groups such as fluoro group, chloro group, bromo group, iodo group, trifluoromethyl group, trifluoroethyl group, trifluoropropyl group, trifluorobutyl group and trichlorobutyl group. [0068]
Neighboring substituent groups among R1 to R4 may be linked together to form an aliphatic ring. Such substituted cyclopentadienyl groups include tetrahydroindenyl, 2-methyltetrahydroindenyl, 2,2, 4-trimethyltetrahydroindenyl, 4-phenyltetrahydroindenyl,
2-methyl-4-phenyltetrahydroindenyl, and a substituted cyclopentadienyl group in which R3 and R4 are tetramethylene groups linking together to form a ring and R1 and R2 are tetramethylene groups linking together to form a ring. [0069]
In Formulae [2] to [7] below, R7 to R16 are selected from a hydrogen atom, hydrocarbon groups, silicon-containing groups, heteroatom-containing groups and halogen-containing groups
and are the same or different from one another, but they are not aryl groups. Examples of the hydrocarbon groups, the silicon-containing groups, the heteroatom-containing groups and the halogen-containing groups are as described above. [0070]
D and E are selected from divalent heteroatoms. Exemplary divalent heteroatoms are an oxygen atom and a sulfur atom. G and L are selected from trivalent heteroatoms. Exemplary trivalent heteroatoms are a nitrogen atom and a phosphorus atom. T and W are selected from tetravalent heteroatoms and a carbon atom. An exemplary tetravalent heteroatom is a silicon atom. [0071]
(Formula Removed)
[0072]
(Formula Removed)
[0073]
(Formula Removed)
[0074]
(Formula Removed)
[0075]
(Formula Removed)
[0076]
(Formula Removed)
[0077]
Examples of the groups represented by Formula [2] include ethoxy group, n-propoxy group, n-butoxy group, isobutoxy group, t-butoxy group, n-pentyloxy group, 2-neopentyloxy group, n-hexyloxy group, n-heptyloxy group, n-octyloxy group, n-nonyloxy group, n-decanyloxy group, 3, 3, 3-trif luoropropoxy group, 4-phenylbutoxy group, ethylsulfanyl group, n-propylsulfanyl group, n-butylsulfanyl group, isobutylsulfanyl group, t-butylsulfanyl group, n-pentylsulfanyl group, 2-neopentylsulfanyl group, n-hexylsulfanyl group, n-heptylsulfanyl group, n-octylsulfanyl group, n-nonylsulfanyl group, n-decanylsulfanyl group, 3,3,3-trifluoropropylsulfanyl group and 4-phenylbutylsulfanyl group. [0078]
Examples of the groups represented by Formula [3] include methoxymethyl group, ethoxymethyl group, n-propoxymethyl group, n-butoxymethyl group, isobutoxymethyl group, t-butoxymethyl group, n-pentyloxymethyl group, 2-neopentyloxymethyl group, n-hexyloxymethyl group, n-heptyloxymethyl group, n-octyloxymethyl group, n-nonyloxymethyl group, n-decanyloxymethyl group, 3,3,3-trifluoropropoxymethyl group, 4-phenylbutoxymethyl group, methylsulfanylmethyl group, ethylsulfanylmethyl group,
n-butylsulfanylmethyl group, isobutylsulfanylmethyl group, t-butylsulfanylmethyl group, n-pentylsulfanylmethyl group, 2-neopentylsulfanylmethyl group, n-hexylsulfanylmethyl group, n-heptylsulfanylmethyl group, n-octylsulfanylmethyl group, n-nonylsulfanylmethyl group, n-decanylsulfanylmethyl group, 3,3,3-trifluoropropylsulfanylmethyl group and 4-phenylbutylsulfanylmethyl group.
[0079]
Examples of the groups represented by Formula [4] include
N-ethyl-N-methylamino group, N-(n-propyl)-N-methylamino
group, (ethyl)(methyl)phosphinomethyl group,
N-(n-butyl)-N-methylamino group, N-(isobutyl)-N-methylamino
group, N-(t-butyl)-N-methylamino group,
N-(n-pentyl)-N-methylamino group,
N-(2-neopentyl)-N-methylamino group,
N-(n-hexyl)-N-methylamino group, N-(n-heptyl)-N-methylamino
group, N-(n-octyl)-N-methylamino group,
N-(n-nonyl)-N-methylamino group,
N-(n-decanyl)-N-methylamino group,
N-(3,3,3-trifluoropropyl)-N-methylamino group,
N-(4-phenylbutyl)-N-methylamino group,
(ethyl)(methyl)phosphino group, diethylphosphino group,
(n-propyl)(methyl)phosphino group,
(n-butyl)(methyl)phosphino group,
(n-propyl)(methyl)phosphino group,
(n-butyl)(methyl)phosphino group,
(isobutyl)(methyl)phosphino group,
(t-butyl)(methyl)phosphino group,
(n-pentyl)(methyl)phosphino group,
(2-neopentyl)(methyl)phosphino group,
(n-hexyl)(methyl)phosphino group,
(n-heptyl)(methyl)phosphino group,
(n-octyl)(methyl)phosphino group,
(n-nonyl)(methyl)phosphino group,
(n-decanyl)(methyl)phosphino group,
(3,3,3-trifluoropropyl)(methyl)phosphino group and
(4-phenylbutyl)(methyl)phosphino group.
[0080]
Examples of the groups represented by Formula [5] include N,N-dimethylaminomethyl group, N-ethyl-N-methylaminomethyl group, N-(n-propyl)-N-methylaminomethyl group,
(ethyl)(methyl)phosphinomethyl group, N-(n-butyl)-N-methylaminomethyl group, N-(isobutyl)-N-methylaminomethyl group, N-(t-butyl)-N-methylaminomethyl group, N-(n-pentyl)-N-methylaminomethyl group, N-(2-neopentyl)-N-methylaminomethyl group, N-(n-hexyl)-N-methylaminomethyl group,

N-(n-heptyl)-N-methylaminomethyl group, N-(n-octyl)-N-methylaminomethyl group, N-(n-nonyl)-N-methylaminomethyl group, N-(n-decanyl)-N-methylaminomethyl group, N-(3,3,3-trifluoropropyl)-N-methylaminomethyl group, N-(4-phenylbutyl)-N-methylaminomethyl group, (ethyl)(methyl)phosphinomethyl group, diethylphosphinomethyl group, (n-propyl)(methyl)phosphinomethyl group, (n-butyl)(methyl)phosphinomethyl group, (n-propyl)(methyl)phosphinomethyl group, (n-butyl)(methyl)phosphinomethyl group, (isobutyl)(methyl)phosphinomethyl group, (t-butyl)(methyl)phosphinomethyl group, (n-pentyl)(methyl)phosphinomethyl group, (2-neopentyl)(methyl)phosphinomethyl group, (n-hexyl)(methyl)phosphinomethyl group, (n-heptyl)(methyl)phosphinomethyl group, (n-octyl)(methyl)phosphinomethyl group, (n-nonyl)(methyl)phosphinomethyl group, (n-decanyl)(methyl)phosphinomethyl group,
(3,3,3-trifluoropropyl)(methyl)phosphinomethyl group and (4-phenylbutyl)(methyl)phosphinomethyl group. [0081]
Examples of the groups represented by Formula [6] include n-propyl group, n-butyl group, isobutyl group, t-butyl group, n-pentyl group, 2-neopentyl group, n-hexyl group, n-heptyl group, n-octyl group, n-nonyl group, n-decanyl group, 4,4,4-trifluorobutyl group, 4-phenylbutyl group,
ethyldimethylsilyl group, n-propyldimethylsilyl group,
n-butyldimethylsilyl group, isobutyldimethylsilyl group,
t-butyldimethylsilyl group, n-pentyldimethylsilyl group,
2-neopentyldimethylsilyl group, n-hexyldimethylsilyl group,
n-heptyldimethylsilyl group, n-octyldimethylsilyl group,
n-nonyldimethylsilyl group, n-decanyldimethylsilyl group,
3,3,3-trifluoropropyldimethylsilyl group and
4-phenylbutyldimethylsilyl group.
[0082]
Examples of the groups represented by Formula [7] include
n-propyl group, n-butyl group, isobutyl group, t-butyl group,
n-pentyl group, 2-neopentyl group, n-hexyl group, n-heptyl
group, n-octyl group, n-nonyl group, n-decanyl group,
4,4,4-trifluorobutyl group, 4-phenylbutyl group,
ethyldimethylsilylmethyl group, n-propyldimethylsilylethyl
group, n-butyldimethylsilylethyl group,
isobutyldimethylsilylethyl group, t-butyldimethylsilylethyl
group, n-pentyldimethylsilylethyl group,
2-neopentyldimethylsilylethyl group,
n-hexyldimethylsilylethyl group, n-heptyldimethylsilylethyl
group, n-octyldimethylsilylethyl group,
n-nonyldimethylsilylethyl group,
n-decanyldimethylsilylethyl group,
3,3,3-trifluoropropyldimethylsilylethyl group and
4-phenylbutyldimethylsilylethyl group.
[0083]
In a preferred embodiment, R1 to R4 are selected from a hydrogen atom, hydrocarbon groups and halogen-containing groups, and at least one of R1 to R4 is a hydrocarbon group. In a more preferred embodiment, R1 to R4 are each a hydrogen atom or a Cl-15 hydrocarbon group. In a still more preferred embodiment, three substituent groups of R1 to R4 are hydrogen atoms and the other is a Cl-15 hydrocarbon group. In a particularly preferred embodiment, three substituent groups of R1 to R4 are hydrogen atoms and the other is a C3-15 hydrocarbon group. [0084]
In Formula (1), Q1 is a divalent group linking the two ligands and is selected from Cl-20 hydrocarbon groups such as alkylene groups, substituted alkylene groups and alkylidene groups; halogen-containing groups; silicon-containing groups; germanium-containing groups; and tin-containing groups. [0085]
Examples of the alkylene groups, substituted alkylene groups and alkylidene groups each having 1 to 20 carbon atoms include alkylene groups such as methylene, ethylene, propylene and butylene; substituted alkylene groups such as isopropylidene, diethylmethylene, dipropylmethylene, diisopropylmethylene, dibutylmethylene, methylethylmethylene, methylbutylmethylene, methyl-t-butylmethylene, dihexylmethylene, dicyclohexylmethylene, methylcyclohexylmethylene, methylphenylmethylene, diphenylmethylene, ditolylmethylene, methylnaphthylmethylene, dinaphthylmethylene, 1-methylethylene, 1,2-dimethylethylene and l-ethyl-2-methylethylene; cycloalkylidene groups such as cyclopropylidene, cyclobutylidene, cyclopentylidene, cyclohexylidene, cycloheptylidene, bicyclo[3.3.1]nonylidene, norbornylidene, adamantylidene, tetrahydronaphthylidene and dihydroindanylidene; and alkylidene groups such as ethylidene, propylidene and butylidene. [0086]
Examples of the halogen-containing groups include groups corresponding to the above alkylene groups, substituted alkylene groups and alkylidene groups or silicon-containing groups except that at least one hydrogen atom is substituted with an appropriate halogen atom. Specific examples include
bis (trifluoromethyl)methylene, 4,4,4-trifluorobutylmethylmethylene, bis (trifluoromethyl)silylene and 4,4,4-trifluorobutylmethylsilylene. [0087]
Examples of the silicon-containing groups include silylene, methylsilylene, dimethylsilylene, diisopropylsilylene, dibutylsilylene, methylbutylsilylene, methyl-t-butylsilylene, dicyclohexylsilylene, methylcyclohexylsilylene, methylphenylsilylene, diphenylsilylene, ditolylsilylene, methylnaphthylsilylene, dinaphthylsilylene, cyclodimethylenesilylene, cyclotrimethylenesilylene, cyclotetramethylenesilylene, cyclopentamethylenesilylene, cyclohexamethylenesilylene and cycloheptamethylenesilylene. Examples of the germanium- or tin-containing groups include groups corresponding to the above silicon-containing groups except that the silicon is replaced by germanium or tin. [0088]
Alternatively, Q1 may have a structure represented by Formula [8] or [9] below: [0089]
(Formula Removed)
[0090]
(Formula Removed)
[0091]
In the above formulae, Y is selected from a carbon atom, a silicon atom, a germanium atom and a tin atom; R5 and R6 are selected from a hydrogen atom, hydrocarbon groups, silicon-containing groups, heteroatom-containing groups and halogen-containing groups and are the same or different from each other; A indicates a C2-20 divalent hydrocarbon group which may have an unsaturated bond; A may have two or more ring structures inclusive of the ring formed by A and Y; and the
black dots (•) indicate bonding points with the substituted cyclopentadienyl group and the cyclopentadienyl group. [0092]
In Formulae [8] and [9], Y is preferably a carbon atom
or a silicon atom, and is particularly preferably a silicon
atom.
[0093]
Examples of the hydrocarbon groups, the silicon-containing groups, the heteroatom-containing groups and the halogen-containing groups indicated by R5 and R6 in Formula [8] include similar groups as represented by R1, R2, R3 and R4. Of the hydrocarbon groups, methyl group, chloromethyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, isobutyl group, t-butyl group, n-pentyl group, cyclopentyl group, cyclohexyl group, cycloheptyl group, phenyl group, m-tolyl group and p-tolyl group are preferable, and methyl group, chloromethyl group, n-butyl group, n-pentyl group and phenyl group are particularly preferred. [0094]
In Formula [9], A is a C2-20 divalent hydrocarbon group which may have an unsaturated bond, and Y and A together form a ring such as 1-silacyclopentylidene group. In the specification, the 1-silacyclopentylidene group is represented by Formula [10] below: [0095]
(Formula Removed)
[0096]
In Formula [10], the black dots (•) are as described in Formula [9] .
The group A may have two or more ring structures inclusive of the ring formed by A and Y. [0097]
Preferred groups indicated by Q1 include alkylene groups, substituted alkylene groups, alkylidene groups, halogen-containing alkylene groups, halogen-containing substituted alkylene groups, halogen-containing alkylidene groups, silicon-containing groups and halogen-containing silicon-containing groups each having 1 to 20 carbon atoms, with silicon-containing groups and halogen-containing silicon-containing groups being particularly preferable. [0098]
In Formula (1), X independently at each occurrence is an atom or a group selected from a hydrogen atom, halogen atoms, hydrocarbon groups, anionic ligands and neutral ligands capable of coordination through lone-pair electrons, and the plurality of X may be the same or different from each other.
[0099]
Examples of the halogens include fluorine, chlorine, bromine and iodine. Specific examples of the hydrocarbon groups are as described hereinabove. [0100]
Specific examples of the anionic ligands include alkoxy groups and aryloxy groups such as methoxy, t-butoxy and phenoxy; carboxylate groups such as acetate and benzoate; and sulfonate groups such as mesylate and tosylate. [0101]
Specific examples of the neutral ligands capable of coordination through lone-pair electrons include organophosphorus compounds such as trimethylphosphine, triethylphosphine, triphenylphosphine and
diphenylmethylphosphine; and ethers such as tetrahydrofuran, diethyl ether, dioxane and 1,2-dimethoxyethane. Preferably, at least one X is a halogen atom or an alkyl group. [0102]
In a preferred embodiment, at least one of R1, R2, R3 and R4 in Formula [1] is selected from the ethyl group, the groups represented by Formula [6] and the groups represented by Formula [7] . In a more preferred embodiment, one of R1, R2, R3 and R4 is selected from the ethyl group, the groups of Formula [6] and the groups of Formula [7], and more preferably R2 or R3 is
selected from the ethyl group, the groups represented by Formula [6] and the groups represented by Formula [7]. In a particularly preferred embodiment, R3 is selected from the ethyl group, the groups of Formula [6] and the groups of Formula [7], and R1, R2 and R4 are all hydrogen atoms. [0103]
Specific examples of the transition metal compounds as the components (A) represented by Formula [1] are given below. [0104]
Specific examples include bridged asymmetric metallocene compounds having an alkylene group as the bridging group, such as ethylene(cyclopentadienyl)(2-methylcyclopentadienyl) zirconium dichloride, ethylene(cyclopentadienyl) (3-methylcyclopentadienyl)zirconium dichloride, ethylene(cyclopentadienyl)(2-ethylcyclopentadienyl) zirconium dichloride, ethylene(cyclopentadienyl) (3-ethylcyclopentadienyl)zirconium dichloride, ethylene(cyclopentadienyl)(2-n-propylcyclopentadienyl) zirconium dichloride, ethylene(cyclopentadienyl) (2-n-butylcyclopentadienyl)zirconium dichloride, ethylene(cyclopentadienyl)(3-n-propylcyclopentadienyl) zirconium dichloride, ethylene(cyclopentadienyl) (3-n-butylcyclopentadienyl)zirconium dichloride, ethylene(cyclopentadienyl)(3-n-pentylcyclopentadienyl)
zirconium dichloride, ethylene(cyclopentadienyl)
(3-n-hexylcyclopentadienyl)zirconium dichloride,
ethylene(cyclopentadienyl)(3-n-octylcyclopentadienyl)
zirconium dichloride, ethylene(cyclopentadienyl)
(3-n-decylcyclopentadienyl)zirconium dichloride,
ethylene(cyclopentadienyl)(2,3-dimethylcyclopentadienyl)
zirconium dichloride, ethylene(cyclopentadienyl)
(2,4-dimethylcyclopentadienyl)zirconium dichloride,
ethylene(cyclopentadienyl)(2,5-dimethylcyclopentadienyl)
zirconium dichloride, ethylene(cyclopentadienyl)
(3,4-dimethylcyclopentadienyl)zirconium dichloride,
ethylene(cyclopentadienyl)
(3,4-di-n-propylcyclopentadienyl)zirconium dichloride,
ethylene(cyclopentadienyl)(3,4-di-n-butylcyclopentadienyl)
zirconium dichloride, ethylene(cyclopentadienyl)
(2,3-ethylmethylcyclopentadienyl)zirconium dichloride,
ethylene(cyclopentadienyl)
(2,4-ethylmethylcyclopentadienyl)zirconium dichloride,
ethylene(cyclopentadienyl)
(2,5-ethylmethylcyclopentadienyl)zirconium dichloride,
ethylene(cyclopentadienyl)
(3-methyl-4-n-propylcyclopentadienyl)zirconium dichloride,
ethylene(cyclopentadienyl)
(3-methyl-4-n-butylcyclopentadienyl)zirconium dichloride,
ethylene(cyclopentadienyl)
(2,3,4-trimethylcyclopentadienyl)zirconium dichloride, ethylene(cyclopentadienyl)
(2,3,5-trimethylcyclopentadienyl)zirconium dichloride, ethylene(cyclopentadienyl)
(2,5-dimethyl-3-n-propylcyclopentadienyl)zirconium dichloride, ethylene(cyclopentadienyl) (2,5-dimethyl-3-n-butylcyclopentadienyl)zirconium dichloride, ethylene(cyclopentadienyl) (tetramethylcyclopentadienyl)zirconium dichloride, ethylene(cyclopentadienyl)
(2,5-dimethyl-3,4-di-n-propylcyclopentadienyl)zirconium dichloride and ethylene(cyclopentadienyl) (2,5-dimethyl-3,4-di-n-butylcyclopentadienyl)zirconium dichloride;
bridged asymmetric metallocene compounds having a substituted alkylene group as the bridging group, such as isopropylidene(cyclopentadienyl)(2-methylcyclopentadienyl) zirconium dichloride, isopropylidene(cyclopentadienyl) (3-methylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)(2-ethylcyclopentadienyl) zirconium dichloride, isopropylidene(cyclopentadienyl) (3-ethylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(2-n-propylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(2-n-butylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(3-n-propylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(3-n-butylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(3-n-pentylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(3-n-hexylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(3-n-octylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(3-n-decylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(2,3-dimethylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(2,4-dimethylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(2,5-dimethylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(3,4-dimethylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(3,4-di-n-propylcyclopentadienyl)zirconium dichloride,
isopropylidene(cyclopentadienyl)
(3,4-di-n-butylcyclopentadienyl)zirconium dichloride,
isopropylidene(cyclopentadienyl)
(2,3-ethylmethylcyclopentadienyl)zirconium dichloride,
isopropylidene(cyclopentadienyl)
(2,4-ethylmethylcyclopentadienyl)zirconium dichloride,
isopropylidene(cyclopentadienyl)
(2,5-ethylmethylcyclopentadienyl)zirconium dichloride,
isopropylidene(cyclopentadienyl)
(3-methyl-4-n-propylcyclopentadienyl)zirconium dichloride,
isopropylidene(cyclopentadienyl)
(3-methyl-4-n-butylcyclopentadienyl)zirconium dichloride,
isopropylidene(cyclopentadienyl)
(2,3,4-trimethylcyclopentadienyl)zirconium dichloride,
isopropylidene(cyclopentadienyl)
(2,3,5-trimethylcyclopentadienyl)zirconium dichloride,
isopropylidene(cyclopentadienyl)
(2,5-dimethyl-3-n-propylcyclopentadienyl)zirconium
dichloride, isopropylidene(cyclopentadienyl)
(2,5-dimethyl-3-n-butylcyclopentadienyl)zirconium
dichloride, isopropylidene(cyclopentadienyl)
(tetramethylcyclopentadienyl)zirconium dichloride,
isopropylidene(cyclopentadienyl)
(2,5-dimethyl-3,4-di-n-propylcyclopentadienyl)zirconium dichloride and isopropylidene(cyclopentadienyl) (2,5-dimethyl-3,4-di-n-butylcyclopentadienyl)zirconium dichloride; and
bridged asymmetric metallocene compounds having a silicon-containing group as the bridging group, such as dimethylsilylene(cyclopentadienyl) (2-methylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl) (3-methylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl) (2-ethylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl) (3-ethylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(2-n-propylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl) (2-n-butylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl) (3-n-propylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl) (3-n-butylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl) (3-n-pentylcyclopentadienyl)zirconium dichloride,
dimethylsilylene(cyclopentadienyl) (3-n-hexylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl) (3-n-octylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl) (3-n-decylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(2,3-dimethylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(2,4-dimethylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(2,5-dimethylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(3,4-dimethylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(3,4-di-n-propylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(3,4-di-n-butylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(2,3-ethylmethylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(2,4-ethylmethylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl) (2,5-ethylmethylcyclopentadienyl)zirconium dichloride,
dimethylsilylene(cyclopentadienyl)
(3-methyl-4-n-propylcyclopentadienyl)zirconium dichloride,
dimethylsilylene(cyclopentadienyl)
(3-methyl-4-n-butylcyclopentadienyl)zirconium dichloride,
dimethylsilylene(cyclopentadienyl)
(2,3,4-trimethylcyclopentadienyl)zirconium dichloride,
dimethylsilylene(cyclopentadienyl)
(2,3,5-trimethylcyclopentadienyl)zirconium dichloride,
dimethylsilylene(cyclopentadienyl)
(2,5-dimethyl-3-n-propylcyclopentadienyl)zirconium
dichloride, dimethylsilylene(cyclopentadienyl)
(2,5-dimethyl-3-n-butylcyclopentadienyl)zirconium
dichloride, dimethylsilylene(cyclopentadienyl)
(tetramethylcyclopentadienyl)zirconium dichloride,
dimethylsilylene(cyclopentadienyl)
(2,5-dimethyl-3,4-di-n-propylcyclopentadienyl)zirconium
dichloride and dimethylsilylene(cyclopentadienyl)
(2,5-dimethyl-3,4-di-n-butylcyclopentadienyl)zirconium
dichloride.
[0105]
Examples further include bridged asymmetric metallocene compounds corresponding to the aforesaid compounds except that the isopropylidene bridging group of the substituted alkylene group is altered to a di-n-butylmethylene bridging group;
bridged asymmetric metallocene compounds corresponding to the aforesaid compounds except that the dimethylsilylene bridging group of the silicon-containing group is altered to a di-n-butylsilylene bridging group; bridged asymmetric metallocene compounds corresponding to the aforesaid compounds except that at least one of the hydrogen atoms of the bridging group is replaced by a halogen atom; and bridged asymmetric metallocene compounds corresponding to the aforesaid compounds except that at least one of the hydrogen atoms of the substituent groups bonded to the cyclopentadienyl ring is replaced by a halogen atom. Examples further include bridged metallocene compounds as described above in which the central metal is titanium or hafnium. The compounds described above are not restrictive. [0106]
Of the compounds described above, bridged asymmetric metallocene compounds in which the bridge has a silicon-containing group such as a dimethylsilylene group are preferable, and particularly preferred examples of such compounds include dimethylsilylene(cyclopentadienyl) (3-ethylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl) (3-n-propylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(3-n-butylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(3-n-octylcyclopentadienyl)zirconium dichloride, dibutylsilylene(cyclopentadienyl)
(3-n-propylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(3-n-butylcyclopentadienyl)zirconium dichloride, dimethylsilylene(cyclopentadienyl)
(3-n-octylcyclopentadienyl)zirconium dichloride, trifluoromethylbutylsilylene(cyclopentadienyl)
(3-n-propylcyclopentadienyl)zirconium dichloride, trifluoromethylbutylsilylene(cyclopentadienyl)
(3-n-butylcyclopentadienyl)zirconium dichloride and trifluoromethylbutylsilylene(cyclopentadienyl)
(3-n-octylcyclopentadienyl)zirconium dichloride. In the invention, there may be used two or more kinds of the metallocene compounds of Formula [1] differing in structure from each other, or a mixture of optical isomers (a meso isomer/racemic isomer mixture). The bridged metallocene compounds of the present invention are not limited to the compounds described above and include any other compounds that meet the requirements set forth in the claims of the invention.
[0107]
Processes for producing bridged metallocene compounds
The bridged metallocene compounds of the invention may be produced by any methods without limitation. For example, reference may be made to WO 01/027124. As an example, a compound represented by Formula [1] in which Q1 is a structure of Formula [8] or [ 9] may be manufactured by the following steps . [0108]
First, a precursor compound (10) or (19) for Formula [1] may be produced by a process [A] or [C]. [0109]
When Y is carbon, a precursor compound (10) or (19) for Formula [1] may be produced by a process [B] or [D]. [0110]
(Formula Removed)
[0111]
(Formula Removed)
[0112]
(Formula Removed)
[0113]
(Formula Removed)
[0114]
In the formulae above, R1 to R6 and Y are the same as described in Formulae [8] and [9]; L is an alkali metal or an alkaline earth metal; Z1 and Z2 are each a halogen or an anionic ligand and may be the same or different from each other; and the compounds (10) and (19) have isomers differing in the position of the double bonds in the cyclopentadienyl rings, and although the above formulae show only one kind of such isomers, other isomers differing in the position of the double bonds in the cyclopentadienyl rings or mixtures of such isomers may be used.
Examples of the alkali metals used in the reactions [A] to [D] include lithium, sodium and potassium, and examples of the alkaline earth metals include magnesium and calcium.
Examples of the halogens include fluorine, chlorine, bromine and iodine. Examples of the anionic ligands include alkoxy groups such as methoxy, tert-butoxy and phenoxy; carboxylate groups such as acetate and benzoate; and sulfonate groups such as mesylate and tosylate. [0115]
The metallocene compounds may be produced from the precursor compounds (10) or (19) as illustrated in Formula [E] or [F] . These processes do not limit the scope of the invention, and the metallocene compounds may be synthesized by any other known methods. [0116]
(Formula Removed)
[0117]
The precursor compound (10) or (19) obtained by any of the reactions [A] to [D] is brought into contact with an alkali metal, an alkali metal hydride or an organic alkali metal in an organic solvent at a reaction temperature of -80 to 200°C to give a dialkali metal salt. [0118]
The organic solvents used in the above reaction include aliphatic hydrocarbons such as pentane, hexane, heptane, cyclohexane and decalin; aromatic hydrocarbons such as benzene, toluene and xylene; ethers such as THF, di-n-butyl ether, cyclopentylmethyl ether, dioxane and 1,2-dimethoxyethane; and halogenated hydrocarbons such as dichloromethane and chloroform. [0119]
The alkali metals used in the above reaction include lithium, sodium and potassium. The alkali metal hydrides include sodium hydride and potassium hydride. The organic alkali metals include methyllithium, butyllithium and phenyllithium. [0120]
Next, the dialkali metal salt (28) or (30) is subjected to the subsequent reaction, preferably after purification. The purification may be performed with solvents such as aliphatic hydrocarbons such as pentane, hexane, heptane,
cyclohexane and decalin; aromatic hydrocarbons such as benzene, toluene and xylene; ethers such as THF, di-n-butyl ether, dioxane and 1, 2-dimethoxyethane; and halogenated hydrocarbons such as dichloromethane and chloroform. Of these solvents, the aliphatic hydrocarbons such as pentane, hexane, heptane, cyclohexane and decalin are more preferable. [0121]
In the subsequent reaction, the dialkali metal salt (28) or (30) is reacted in an organic solvent with a compound represented by Formula (32): MXk ••• (32)
wherein M is a metal selected from titanium, zirconium and hafnium; a plurality of X are halogens, anionic ligands and neutral ligands capable of coordination through lone-pair electrons and may be the same or different from one another; and k is an integer of 3 to 6. The reaction results in a bridged metallocene compound of Formula [1] . To prevent the formation of by-products, preferred organic solvents are aliphatic hydrocarbons such as pentane, hexane, heptane, cyclohexane and decalin, and mixed solvents containing aliphatic hydrocarbons at not less than 50 wt% and ethers. The aliphatic hydrocarbons such as pentane, hexane, heptane, cyclohexane and decalin are particularly preferred. [0122]
Preferred examples of the compounds represented by Formula (32) are trivalent or tetravalent titanium fluoride, chloride, bromide and iodide; tetravalent zirconium fluoride, chloride, bromide and iodide; tetravalent hafnium fluoride, chloride, bromide and iodide; and complexes of these halides with ethers such as THF, di-n-butyl ether, dioxane and 1,2-dimethoxyethane. [0123]
The organic solvents used herein are similar to those described hereinabove. The dialkali metal salt and the compound of Formula (32) are preferably reacted in equimolar amounts in the organic solvent at a reaction temperature of -80 to 200°C. [0124]
The metallocene compound from the reaction may be isolated and purified by methods such as extraction, recrystallization and sublimation. The bridged metallocene compounds according to the invention obtained by the above processes may be identified by techniques such as proton nuclear magnetic resonance spectroscopy, 13C nuclear magnetic resonance spectroscopy, mass spectrometry and elemental analysis. [0125] Olefin polymerization catalysts (a)
The olefin polymerization catalysts (a) contain the components (A) and (C). [0126]
Component (A): the bridged metallocene compound represented by Formula [1] above.
Component (C): at least one compound selected from the group consisting of:
(c-1) organometallic compounds represented by Formulae [11], [12] and [13] below;
(c-2) organoaluminum oxy-compounds; and
(c-3) compounds that react with the component (A) to form an ion pair; [0127]
(Formula Removed)
[0128]
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; X is a halogen atom; 0 (Formula Removed)
[0130]
wherein Ma is Li, Na or K; and Ra is a Cl-15 hydrocarbon
group; [0131]
(Formula Removed)
[0132]
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; Mb is selected from Mg, Zn and Cd; X is a halogen atom; 0 The olefin polymerization catalysts may further contain a solid carrier (S) as required. [0133]
The component (C) and the solid carrier (S) will be described in detail below. [0134] Components (C)
The compounds (c-1) may be those compounds disclosed in JP-A-H11-315109 and EP0874005A filed by the present applicant. [0135]
Of the organometallic compounds (c-1) represented by Formulae [11], [12] and [13], those having Formula [11] are preferable. Specific examples thereof include trialkylaluminums such as trimethylaluminum, triethylaluminum, triisopropylaluminum, triisobutylaluminum, trihexylaluminum,
trioctylaluminum and tri-2-ethylhexylaluminum; dialkylaluminum halides such as dimethylaluminum chloride, diethylaluminum chloride, diisopropylaluminum chloride, diisobutylaluminum chloride and dimethylaluminum bromide; alkylaluminum sesquihalides such as methylaluminum sesquichloride, ethylaluminum sesquichloride, isopropylaluminum sesquichloride, butylaluminum sesquichloride and ethylaluminum sesquibromide; alkylaluminum dihalides such as methylaluminum dichloride, ethylaluminum dichloride, isopropylaluminum dichloride and ethylaluminum dibromide; alkylaluminum hydrides such as dimethylaluminum hydride, diethylaluminum hydride, dihydrophenylaluminum hydride, diisopropylaluminum hydride, di-n-butylaluminum hydride, diisobutylaluminum hydride, diisohexylaluminum hydride, diphenylaluminum hydride, dicyclohexylaluminum hydride, di-sec-heptylaluminum hydride and
di-sec-nonylaluminum hydride; and dialkylaluminum alkoxides such as dimethylaluminum ethoxide, diethylaluminum ethoxide, diisopropylaluminum methoxide and diisobutylaluminum ethoxide. [0136]
These compounds may be used singly, or two or more kinds may be used in combination. [0137]

Preferred organoaluminum oxy-compounds (c-2) are aluminoxanes prepared from trialkylaluminums or tricycloalkylaluminums. In particular, organoaluminum oxy-compounds prepared from trimethylaluminum or triisobutylaluminum are preferable. The organoaluminum oxy-compounds may be used singly, or two or more kinds may be used in combination. [0138]
Examples of the compounds (c-3) capable of reacting with the component (A) to form an ion pair include Lewis acids, ionic compounds, borane compounds and carborane compounds as described in JP-A-H01-501950, JP-A-H01-502036, JP-A-H03-179005, JP-A-H03-179006, JP-A-H03-207703, JP-A-H03-207704, and U.S. Patent No. 5,321,106. Heteropoly compounds and isopoly compounds may also be employed. These compounds may be used without limitation. [0139]
When the olefin polymerization catalyst of the invention is used together with an organoaluminum oxy-compound such as methylaluminoxane as a cocatalyst component, the catalyst shows very high polymerization activity for olefin compounds. Further, an organoaluminum oxy-compound reacts with the active hydrogen in the solid carrier, and a solid carrier component containing the cocatalyst component may be prepared easily.
In view of these advantages, it is preferable to use the
organoaluminum oxy-compound (c-2) as component (C) .
[0140]
Solid carriers (S)
The solid carriers (S) will be described next. The solid carriers (S) may be simply referred to as the components (S) . [0141]
The solid carrier (S) optionally used in the invention is an inorganic or organic compound in the form of granular or fine particulate solid. The components described hereinabove are supported on the solid carrier. [0142]
Examples of the inorganic compounds include porous oxides, inorganic halides, clays, clay minerals and ion-exchange layered compounds. Preferably, porous oxides or inorganic halides described below are used. [0143]
Examples of the porous oxides include Si02, AI2O3, MgO, ZrO, Ti02, B203, CaO, ZnO, BaO, Th02, and complexes and mixtures containing these oxides, such as natural or synthetic zeolites, Si02-MgO, Si02-Al203, Si02-Ti02, Si02-V205/ Si02-Cr203 and Si02-Ti02-MgO. Of these, those containing Si02 as the major component are preferable. [0144]
The inorganic oxides may contain small amounts of carbonate, sulfate, nitrate or oxide components such as Na2C03, K2C03, CaC03, MgC03, Na2S04, A12(S04)3, BaS04, KN03, Mg(N03)2, A1(N03)3, Na20, K20 and Li20. [0145]
Although these porous oxides have various properties depending on the type and preparation process thereof, the carrier suitable for use in the invention has a particle
diameter of 0.2 to 300 (am, preferably 1 to 200 fj.m, a specific surface area of 50 to 1200 m2/g, preferably 100 to 1000 m2/g, and a pore volume of 0.3 to 30 cm3/g. Where necessary, the carrier may be calcined at 100 to 1000°C, and preferably 150 to 700°C before use. [0146]
Examples of the inorganic halides include MgCl2, MgBr2, MnCl2 and MnBr2. The inorganic halides may be used as they are or after pulverized by a ball mill, a vibration mill or the like. Alternatively, the inorganic halides may be dissolved in a solvent such as an alcohol and then precipitated by a precipitating agent to be used in the form of fine particles. [0147]
The clays are generally comprised of a clay mineral as the major component. The ion-exchange layered compounds have a crystal structure in which planes formed by ionic bonding
or the like pile on one another in parallel with a weak bond strength, and they contain exchangeable ions. Most clay minerals are ion-exchange layered compounds. The clays, the clay minerals and the ion-exchange layered compounds are not limited to naturally occurring materials and may be synthetic. [0148]
Examples of such clays, clay minerals and ion-exchange layered compounds include clays, clay minerals, and ion crystalline compounds having such a layered crystal structure as a hexagonal closest packing type, an antimony type, a CdCl2 type or a Cdl2 type. [0149]
Specific examples of the clays and the clay minerals include kaolin, bentonite, kibushi clay, potter's clay, allophane, hisingerite, pyrophyllite, mica group, montmorillonite group, vermiculite, chlorite group, palygorskite, kaolinite, nacrite, dickite and halloysite. Specific examples of the ion-exchange layered compounds include crystalline acid salts of polyvalent metals, such as a-Zr (HAs04)2-H20, a-Zr(HP04)2, a-Zr (KP04) 2 • 3H20, a-Ti (HP04) 2, a-Ti(HAs04)2-H20, a-Sn(HP04)2-H20, Y-Zr(HP04)2, y-Ti(HP04)2 and y-Ti(NH4P04)2-H20. [0150]
The clays, the clay minerals and the ion-exchange layered
compounds preferably have a pore volume, as measured on pores having a radius of not less than 20 A by a mercury penetration method, of 0.1 cc/g or more, particularly from 0.3 to 5 cc/g. The pore volume is measured on the pores having a radius of 20 to 3 x 104 A by a mercury penetration method using a mercury porosimeter. [0151]
When the carrier used has a pore volume of less than 0.1 cc/g as measured on pores having a radius of 20 A or more, it tends to be difficult to obtain high polymerization activity. [0152]
It is preferable that the clays and the clay minerals are chemically treated. Any chemical treatment may be used herein, for example a surface treatment to remove impurities attached to the surface or a treatment to affect the crystal structure of the clay. Specific examples of such chemical treatments include acid treatment, alkali treatment, salt treatment and organic matter treatment. The acid treatment removes impurities from the surface and increases the surface area by dissolving cations such as of Al, Fe and Mg from the crystal structure. The alkali treatment destroys the crystal structure of the clay to bring about change in clay structure. The salt treatment and the organic matter treatment produce an ionic complex, a molecular complex or an organic derivative
to cause change in surface area or interlayer distance. [0153]
The ion-exchange layered compound may be enlarged in interlayer distance by changing the exchangeable ions between layers with other larger and bulkier ions by means of ion exchange properties. The bulky ions play a pillar-like roll to support the layered structure and are called pillars. Introduction of other substances between layers of a layered compound is called intercalation. Examples of the guest compounds to be intercalated include cationic inorganic compounds such as TiCl4 and ZrCl4; metal alkoxides such as Ti(OR)4, Zr(OR)4, PO(OR)3 and B(OR)3 (wherein R is a hydrocarbon group or the like); and metal hydroxide ions such as [Al1304(OH)24]7+, [Zr4(OH)14]2+ and [Fe30 (OCOCH3) 6] + . These compounds may be used singly or in combination of two or more kinds. Intercalation of these compounds can be carried out in the presence of polymers obtained by hydrolysis of metal alkoxides such as Si(OR)4, Al(OR)3 and Ge(OR)4 (wherein R is a hydrocarbon group or the like) or in the presence of colloidal inorganic compounds such as Si02. Examples of the pillars include oxides resulting from thermal dehydration of the above-mentioned metal hydroxide ions intercalated between layers. [0154]
The clays, the clay minerals and the ion-exchange layered compounds mentioned above may be used as they are or after treated by, for example, ball milling or sieving. They may be used after subjected to water adsorption or thermal dehydration. The clays, the clay minerals and the ion-exchange layered compounds may be used singly or in combination of two or more kinds. [0155]
The organic compound is, for example, a granular or fine particulate solid ranging in particle diameter from 10 to 300
fim. Specific examples thereof include (co)polymers mainly composed of a C2-14 olefin such as ethylene, propylene, 1-butene or 4-methyl-l-pentene, (co)polymers or reaction products formed mainly of vinylcyclohexane, styrene or divinylbenzene, and modified products of these compounds. [0156]
The olefin polymerization catalysts of the invention contain the bridged metallocene compound (A), at least one compound (C) selected from the organometallic compounds (c-1) of Formulae [11], [12] and [13], the organoaluminum oxy-compounds (c-2) and the ionized ionic compounds (c-3), and optionally the components (S) as required. [0157]
In carrying out the polymerization, the components may
be used and added by any method or in any order. Some exemplary
processes are given below:
[0158]
(1) The component (A) alone is added to a polymerizer. [0159]
(2) The component (A) and the component (C) are added to a polymerizer in an arbitrary order.
[0160]
(3) A catalyst component in which the component (A) is
supported on the component (S) , and the component (C) are added
to a polymerizer in an arbitrary order.
[0161]
(4) A catalyst component in which the component (C) is
supported on the component (S) , and the component (A) are added
to a polymerizer in an arbitrary order.
[0162]
(5) A catalyst component in which the components (A) and
(C) are supported on the component (S) is added to a polymerizer.
[0163]
In the processes (2) to (5) , at least two of the catalyst components may be contacted with each other beforehand. [0164]
In the processes (4) and (5) in which the component (C) is supported on the carrier, other unsupported component (C)
may be added at an arbitrary stage as required. In this case, these components (C) may be the same or different from each other. [0165]
The solid catalyst component wherein the component (A) alone or the components (A) and (C) are supported on the component (S) may be prepolymerized with an olefin. Further, an additional catalyst component may be supported on the prepolymerized solid catalyst component. [0166]
In general, when a metallocene compound having substituent groups on both the cyclopentadienyl rings forms an ion pair with the component (C), the resultant olefin polymerization catalyst gives with high catalytic activity polymers having high molecular weight and less terminal double bonds. [0167]
The mechanism of this catalytic action is probably explained as follows. A number of substituent groups on the cyclopentadienyl rings produce steric hindrance which causes an appropriate distance between the central metal (cation) and the component (C) (anion) and consequently the acidity of the central metal is increased. As a result, the coordination and insertion of monomers are facilitated but at the same time the
steric hindrance by the substituent groups inhibits chain transfer reactions which control the molecular weight such as a chain transfer reaction of monomers or a transfer of hydrogen at the p-position of the polymer chain to the central metal. [0168]
In contrast, the olefin polymerization catalysts (a) containing the bridged metallocene compound of Formula [1] have substituent groups on only one cyclopentadienyl ring. As a result, an appropriate distance is ensured between the central metal and the component (C) while ensuring an appropriate space to permit chain transfer reactions. The olefin polymerization catalysts of the present invention can thus achieve high polymerization activity and afford polymers having a low molecular weight and many double bonds at terminals. [0169] Olefin polymerization catalysts (b)
The olefin polymerization catalysts (b) of the invention contain the component (A) , the component (B) and the component (C) . [0170]
Component (A) : the bridged metallocene compound represented by Formula [1] above;
Component (B): a bridged metallocene compound represented by Formula [14] below:
[0171]
(Formula Removed)
[0172]
wherein R17 to R20, and R21 to R28 are selected from a hydrogen atom, hydrocarbon groups, halogen-containing groups, oxygen-containing groups, nitrogen-containing groups, boron-containing groups, sulfur-containing groups, phosphorus-containing groups, silicon-containing groups, germanium-containing groups and tin-containing groups and are the same or different from one another; neighboring substituent groups among these groups may be linked together to form a ring; Q2 is selected from Cl-20 hydrocarbon groups, halogen-containing groups, silicon-containing groups, germanium-containing groups and tin-containing groups; M is selected from a titanium atom, a zirconium atom and a hafnium atom; and X independently at each occurrence is a group selected from a hydrogen atom, halogen atoms, hydrocarbon groups, halogen-containing groups, silicon-containing groups,
oxygen-containing groups, sulfur-containing groups, nitrogen-containing groups and phosphorus-containing groups;
Component (C): at least one compound selected from the group consisting of:
(c-1) organometallic compounds represented by Formulae [18], [19] and [20] below;
(c-2) organoaluminum oxy-compounds; and
(c-4) compounds that react with the components (A) and (B) to form an ion pair; [0173]
(Formula Removed)
[0174]
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; X is a halogen atom; 0 (Formula Removed)
[0176]
wherein Ma is Li, Na or K; and Ra is a Cl-15 hydrocarbon group; [0177]
(Formula Removed)
[0178]
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; Mb is selected from
Mg, Zn and Cd; X is a halogen atom; 0 The olefin polymerization catalysts may further contain a solid carrier (S) as required. [0179]
The component (B) , the component (C) and the solid carrier (S) will be described in detail below. [0180] Component (B)
The bridged metallocene compounds as the components (B) are metallocene compounds of Group IV metal represented by Formula [14] below. [0181]
The metallocene compounds of Group IV metal represented by Formula [14] will be described in detail. [0182]
(Formula Removed)
[0183]
In Formula [14], M is a transition metal selected from titanium, zirconium and hafnium, and is preferably zirconium. [0184]
R17 to R20, and R21 to R28 are selected from a hydrogen atom, hydrocarbon groups, halogen-containing groups, oxygen-containing groups, nitrogen-containing groups, boron-containing groups, sulfur-containing groups, phosphorus-containing groups, silicon-containing groups, germanium-containing groups and tin-containing groups and are the same or different from one another. Neighboring two substituent groups among these groups may be linked together to form a ring. [0185]
Q2 is a divalent group linking the two ligands and is selected from Cl-20 hydrocarbon groups such as alkylene groups, substituted alkylene groups and alkylidene groups;
halogen-containing groups; silicon-containing groups; germanium-containing groups; and tin-containing groups. Examples of these groups are as described for Q1. [0186]
Preferred groups indicated by Q2 include alkylene groups, substituted alkylene groups, alkylidene groups, halogen-containing alkylene groups, halogen-containing substituted alkylene groups and halogen-containing alkylidene groups each having 1 to 20 carbon atoms, and silicon-containing groups and halogen-containing silicon-containing groups. Of these, alkylene groups, substituted alkylene groups, alkylidene groups and silicon-containing groups each having 1 to 20 carbon atoms are particularly preferable. [0187]
Alternatively, Q2 may have a structure represented by Formula [15] or [16] below: [0188]
(Formula Removed)
[0189]
(Formula Removed)
[0190]
In the above formulae, Y is selected from a carbon atom, a silicon atom, a germanium atom and a tin atom; R29 and R30 are selected from a hydrogen atom, hydrocarbon groups, silicon-containing groups, heteroatom-containing groups and halogen-containing groups and are the same or different from each other; A' indicates a C2-20 divalent hydrocarbon group which may have an unsaturated bond; A' may have two or more ring structures inclusive of the ring formed by A' and Y; and
the black dots (•) indicate bonding points with the substituted cyclopentadienyl group and the substituted fluorenyl group. [0191]
In Formulae [15] and [16], Y is preferably a carbon atom or a silicon atom, and is particularly preferably a carbon atom. [0192]
Examples of the hydrocarbon groups, the silicon-containing groups, the heteroatom-containing groups and the halogen-containing groups indicated by R29 and R30 in Formula [15] include similar groups as represented by R11 to
R20, and R21 to R28. Of the hydrocarbon groups, methyl group, chloromethyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, isobutyl group, t-butyl group, n-pentyl group, cyclopentyl group, cyclohexyl group, cycloheptyl group, phenyl group, m-tolyl group and p-tolyl group are preferable, and methyl group, chloromethyl group, n-butyl group, n-pentyl group and phenyl group are particularly preferred. [0193]
In Formula [16], A' is a C2-20 divalent hydrocarbon group which may have an unsaturated bond, and Y and A' together form a ring such as 1-silacyclopentylidene group. In the specification, the 1-silacyclopentylidene group is represented by Formula [17] below: [0194]
(Formula Removed)
[0195]
In Formula [17], the black dots (•) are as described in Formula [16].
A' may have two or more ring structures inclusive of the ring formed by A' and Y. [0196]
Preferred groups indicated by Q2 include alkylene groups, substituted alkylene groups, alkylidene groups, halogen-containing alkylene groups, halogen-containing substituted alkylene groups and halogen-containing alkylidene groups each having 1 to 20 carbon atoms, and silicon-containing groups and halogen-containing silicon-containing groups, with carbon-containing groups and halogen-containing carbon groups being particularly preferable. [0197]
The letter X independently at each occurrence is a group selected from a hydrogen atom, halogen atoms, hydrocarbon groups, halogen-containing hydrocarbon groups, silicon-containing groups, oxygen-containing groups, sulfur-containing groups, nitrogen-containing groups and phosphorus-containing groups. Of these, halogen atoms and hydrocarbon groups are preferable. Examples of the halogen atoms include fluorine, chlorine, bromine and iodine. Examples of the hydrocarbon groups, the halogen-containing hydrocarbon groups, the silicon-containing groups, the oxygen-containing groups, the sulfur-containing groups, the nitrogen-containing groups and the phosphorus-containing groups are as described above. [0198]
The hydrogen atom, the hydrocarbon groups, the
halogen-containing groups, the oxygen-containing groups, the nitrogen-containing groups, the boron-containing groups, the sulfur-containing groups, the phosphorus-containing groups, the silicon-containing groups, the germanium-containing groups and the tin-containing groups indicated by R17 to R20, and R21 to R28 may be similar to those represented by R1 to R4 in Formula [1] without limitation. The atoms and the groups indicated by X may be similar to those represented by X in Formula [1] without limitation. In an embodiment, at least one pair of neighboring groups among R17 to R20 on the cyclopentadienyl ring may be linked together to form a ring, and consequently a ring structure such as an indenyl group, a substituted indenyl group, a f luorenyl group or a substituted fluorenyl group may be formed. In another embodiment, at least one pair of neighboring groups among R21 to R28 on the f luorenyl ring may be linked together to form a ring, and consequently a ring structure such as a benzofluorenyl group, a dibenzofluorenyl group, an octahydrodibenzofluorenyl group or an octamethyloctahydrodibenzofluorenyl group may be formed. [0199]
In a preferred embodiment of the above substituent groups, R17 to R20 are hydrogen atoms, R21 to R28 are selected from the hydrogen atom and the hydrocarbon groups, and at least one pair of neighboring hydrocarbon groups may be linked together to
form an octahydrodibenzofluorenyl group or an octamethyloctahydrodibenzofluorenyl group. In a preferred embodiment, Q2 is selected from the alkylene groups, substituted alkylene groups and alkylidene groups having 1 to 20 carbon atoms, and silicon-containing groups. When the bridged metallocene compound has these substituent groups and the bridging group, the obtainable catalyst relatively prevents an increase in molecular weight and permits reducing the amount of hydrogen required for molecular weight control, whereby it is expected that the component (A) affords an increased amount of macromonomers and the number of long-chain branches is increased. [0200]
Specific examples of the Group IV metallocene compounds represented by Formula [14] are given below but are not limited thereto: [0201]
isopropylidene(cyclopentadienyl)(fluorenyl)zirconium dichloride, isopropylidene(cyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(3,6-di-tert-butylfluorenyl)zirconium dichloride, isopropylidene(cyclopentadienyl) (octamethyloctahydridodibenzofluorenyl)zirconium dichloride,
dibutylmethylene(cyclopentadienyl)(fluorenyl)zirconium dichloride, dibutylmethylene(cyclopentadienyl)
(2,7-di-tert-butylfluorenyl)zirconium dichloride, dibutylmethylene(cyclopentadienyl)
(3,6-di-tert-butylfluorenyl)zirconium dichloride, dibutylmethylene(cyclopentadienyl)
(octamethyloctahydridodibenzofluorenyl)zirconium dichloride, diphenylmethylene(cyclopentadienyl)(fluorenyl)zirconium dichloride, diphenylmethylene(cyclopentadienyl)
(2,7-di-tert-butylfluorenyl)zirconium dichloride, diphenylmethylene(cyclopentadienyl)
(3,6-di-tert-butylfluorenyl)zirconium dichloride, diphenylmethylene(cyclopentadienyl)
(octamethyloctahydridodibenzofluorenyl)zirconium dichloride, cyclohexylidene(cyclopentadienyl)(fluorenyl)zirconium dichloride, cyclohexylidene(cyclopentadienyl)
(2,7-di-tert-butylfluorenyl)zirconium dichloride, cyclohexylidene(cyclopentadienyl)
(3,6-di-tert-butylfluorenyl)zirconium dichloride, cyclohexylidene(cyclopentadienyl)
(octamethyloctahydridodibenzofluorenyl)zirconium dichloride, phenylmethylmethylene(cyclopentadienyl)(fluorenyl) zirconium dichloride, phenylmethylmethylene(cyclopentadienyl)

(2,7-di-tert-butylfluorenyl)zirconium dichloride, phenylmethylmethylene(cyclopentadienyl) (3,6-di-tert-butylfluorenyl)zirconium dichloride, phenylmethylmethylene(cyclopentadienyl)
(octamethyloctahydridodibenzofluorenyl)zirconium dichloride, dimethylsilyl(cyclopentadienyl)(fluorenyl)zirconium dichloride, dimethylsilyl(cyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, dimethylsilyl(cyclopentadienyl)
(3,6-di-tert-butylfluorenyl)zirconium dichloride, dimethylsilyl(cyclopentadienyl)
(octamethyloctahydridodibenzofluorenyl)zirconium dichloride, isopropylidene(3-tert-butylcyclopentadienyl)(fluorenyl) zirconium dichloride,
isopropylidene(3-tert-butylcyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, isopropylidene(3-tert-butylcyclopentadienyl) (3,6-di-tert-butylfluorenyl)zirconium dichloride, isopropylidene(3-tert-butylcyclopentadienyl)
(octamethyloctahydridodibenzofluorenyl)zirconium dichloride, diphenylmethylene(3-tert-butylcyclopentadienyl) (fluorenyl)zirconium dichloride,
diphenylmethylene(3-tert-butylcyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride,
diphenylmethylene(3-tert-butylcyclopentadienyl) (3,6-di-tert-butylfluorenyl)zirconium dichloride, diphenylmethylene(3-tert-butylcyclopentadienyl) (octamethyloctahydridodibenzofluorenyl)zirconium dichloride, cyclohexylidene(3-tert-butylcyclopentadienyl) (fluorenyl)zirconium dichloride, cyclohexylidene(3-tert-butylcyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, cyclohexylidene(3-tert-butylcyclopentadienyl) (3,6-di-tert-butylfluorenyl)zirconium dichloride, cyclohexylidene(3-tert-butylcyclopentadienyl) (octamethyloctahydridodibenzofluorenyl)zirconium dichloride, phenylmethylmethylene(3-tert-butylcyclopentadienyl) (fluorenyl)zirconium dichloride,
phenylmethylmethylene(3-tert-butylcyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, phenylmethylmethylene(3-tert-butylcyclopentadienyl) (3,6-di-tert-butylfluorenyl)zirconium dichloride, phenylmethylmethylene(3-tert-butylcyclopentadienyl) (octamethyloctahydridodibenzofluorenyl)zirconium dichloride, isopropylidene(3-tert-butyl-5-methylcyclopentadienyl) (fluorenyl)zirconium dichloride,
isopropylidene(3-tert-butyl-5-methylcyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride,
isopropylidene(3-tert-butyl-5-methylcyclopentadienyl) (3,6-di-tert-butylfluorenyl)zirconium dichloride, isopropylidene(3-tert-butyl-5-methylcyclopentadienyl) (octamethyloctahydridodibenzofluorenyl)zirconium dichloride, diphenylmethylene(3-tert-butyl-5-methylcyclopentadienyl) (fluorenyl)zirconium dichloride,
diphenylmethylene(3-tert-butyl-5-methylcyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, diphenylmethylene(3-tert-butyl-5-methylcyclopentadienyl) (3,6-di-tert-butylfluorenyl)zirconium dichloride, diphenylmethylene(3-tert-butyl-5-methylcyclopentadienyl) (octamethyloctahydridodibenzofluorenyl)zirconium dichloride, cyclohexylidene(3-tert-butyl-5-methylcyclopentadienyl) (fluorenyl)zirconium dichloride,
cyclohexylidene(3-tert-butyl-5-methylcyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, cyclohexylidene(3-tert-butyl-5-methylcyclopentadienyl) (3,6-di-tert-butylfluorenyl)zirconium dichloride, cyclohexylidene(3-tert-butyl-5-methylcyclopentadienyl) (octamethyloctahydridodibenzofluorenyl)zirconium dichloride, phenylmethylmethylene
(3-tert-butyl-5-methylcyclopentadienyl)(fluorenyl) zirconium dichloride, phenylmethylmethylene (3-tert-butyl-5-methylcyclopentadienyl)
(2,7-di-tert-butylfluorenyl)zirconium dichloride, phenylmethylmethylene
(3-tert-butyl-5-methylcyclopentadienyl) (3,6-di-tert-butylfluorenyl)zirconium dichloride, phenylmethylmethylene
(3-tert-butyl-5-methylcyclopentadienyl)
(octamethyloctahydridodibenzofluorenyl)zirconium dichloride, and dibromide compounds, dialkyl compounds, diaralkyl compounds, disilyl compounds, dialkoxy compounds, dithiol compounds, disulfonic acid compounds, diamino compounds and diphosphine compounds of the above metallocene compounds, and compounds corresponding to the above metallocene compounds except that the central metal is replaced by titanium or hafnium. [0202]
Of the above metallocene compounds, preferred are isopropylidene(cyclopentadienyl)(fluorenyl)zirconium dichloride, isopropylidene(cyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(3,6-di-tert-butylfluorenyl)zirconium dichloride, isopropylidene(cyclopentadienyl)
(octamethyloctahydridodibenzofluorenyl)zirconium dichloride, dibutylmethylene(cyclopentadienyl)(fluorenyl)zirconium
dichloride, dibutylmethylene(cyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, dibutylmethylene(cyclopentadienyl) (3,6-di-tert-butylfluorenyl)zirconium dichloride, dibutylmethylene(cyclopentadienyl)
(octamethyloctahydridodibenzofluorenyl)zirconium dichloride, cyclohexylidene(cyclopentadienyl)(fluorenyl)zirconium dichloride, cyclohexylidene(cyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, cyclohexylidene(cyclopentadienyl)
(3,6-di-tert-butylfluorenyl)zirconium dichloride, cyclohexylidene(cyclopentadienyl)
(octamethyloctahydridodibenzofluorenyl)zirconium dichloride, dimethylsilyl(cyclopentadienyl)(fluorenyl)zirconium dichloride, dimethylsilyl(cyclopentadienyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, dimethylsilyl(cyclopentadienyl)
(3,6-di-tert-butylfluorenyl)zirconium dichloride and dimethylsilyl(cyclopentadienyl)
(octamethyloctahydridodibenzofluorenyl)zirconium dichloride. [0203]
Specific examples of the metallocene compounds in which neighboring groups among R17 to R20 on the cyclopentadienyl ring
are linked together to form an indenyl ring or a substituted indenyl ring include isopropylidene(indenyl)(fluorenyl) zirconium dichloride, isopropylidene(indenyl) (2,7-di-tert-butylfluorenyl)zirconium dichloride, isopropylidene(indenyl)(3,6-di-tert-butylfluorenyl) zirconium dichloride, isopropylidene(indenyl) (octamethyloctahydridodibenzofluorenyl)zirconium dichloride, cyclohexylidene(indenyl)(fluorenyl)zirconium dichloride, cyclohexylidene(indenyl)
(2,7-di-tert-butylfluorenyl)zirconium dichloride, cyclohexylidene(indenyl)(3,6-di-tert-butylfluorenyl) zirconium dichloride, cyclohexylidene(indenyl) (octamethyloctahydridodibenzofluorenyl)zirconium dichloride, dimethylsilyl(indenyl)(fluorenyl)zirconium dichloride, dimethylsilyl(indenyl)
(2,7-di-tert-butylfluorenyl)zirconium dichloride, dimethylsilyl(indenyl)(3,6-di-tert-butylfluorenyl) zirconium dichloride and dimethylsilyl(indenyl) (octamethyloctahydridodibenzofluorenyl)zirconium dichloride. In the invention, two or more differing kinds of the metallocene compounds represented by Formula [14] may be used without limitation. [0204]
The bridged metallocene compounds represented by Formula
[14] are disclosed in WO 01/27124.
[0205]
Components (C)
(c-1) Organometallic compounds represented by Formulae [18], [19] and [20];
(c-2) organoaluminum oxy-compounds; and
(c-4) compounds that react with the components (A) and (B) to form an ion pair.
The compounds (c-1) may be those compounds disclosed in JP-A-H11-315109 and EP0874005A filed by the present applicant. [0206]
Of the organometallic compounds (c-1) represented by Formulae [18], [19] and [20], those having Formula [18] are preferable. Specific examples of such compounds include trialkylaluminums such as trimethylaluminum, triethylaluminum, triisopropylaluminum, triisobutylaluminum, trihexylaluminum, trioctylaluminum and tri-2-ethylhexylaluminum; dialkylaluminum halides such as dimethylaluminum chloride, diethylaluminum chloride, diisopropylaluminum chloride, diisobutylaluminum chloride and dimethylaluminum bromide; alkylaluminum sesquihalides such as methylaluminum sesquichloride, ethylaluminum sesquichloride, isopropylaluminum sesquichloride, butylaluminum sesquichloride and ethylaluminum sesquibromide; alkylaluminum
dihalides such as methylaluminum dichloride, ethylaluminum dichloride, isopropylaluminum dichloride and ethylaluminum dibromide; alkylaluminum hydrides such as dimethylaluminum hydride, diethylaluminum hydride, dihydrophenylaluminum hydride, diisopropylaluminum hydride, di-n-butylaluminum hydride, diisobutylaluminum hydride, diisohexylaluminum hydride, diphenylaluminum hydride, dicyclohexylaluminum hydride, di-sec-heptylaluminum hydride and
di-sec-nonylaluminum hydride; and dialkylaluminum alkoxides such as dimethylaluminum ethoxide, diethylaluminum ethoxide, diisopropylaluminum methoxide and diisobutylaluminum ethoxide. [0207]
These compounds may be used singly, or two or more kinds may be used in combination. [0208]
Preferred organoaluminum oxy-compounds (c-2) are aluminoxanes prepared from trialkylaluminums or tricycloalkylaluminums. In particular, organoaluminum oxy-compounds prepared from trimethylaluminum or triisobutylaluminum are preferable. The organoaluminum oxy-compounds may be used singly, or two or more kinds may be used in combination. [0209]
Examples of the compounds (c-4) capable of reacting with the component (A) and the component (B) to form an ion pair include Lewis acids, ionic compounds, borane compounds and carborane compounds as described in JP-A-H01-501950, JP-A-H01-502036, JP-A-H03-179005, JP-A-H03-179006, JP-A-H03-207703, JP-A-H03-207704, and U.S. Patent No. 5,321,106. Heteropoly compounds and isopoly compounds may also be employed. These compounds may be used without limitation. [0210]
When the olefin polymerization catalyst of the invention is used together with an organoaluminum oxy-compound such as methylaluminoxane as a cocatalyst component, the catalyst shows very high polymerization activity for olefin compounds. Further, an organoaluminum oxy-compound reacts with the active hydrogen in the solid carrier, and a solid carrier component containing the cocatalyst component may be prepared easily. In view of these advantages, it is preferable to use the organoaluminum oxy-compound (c-2) as component (C). [0211] Solid carriers (S)
The solid carriers (S) will be described next. The solid carriers (S) may be simply referred to as the components (S) . [0212]
The solid carrier (S) optionally used in the invention is an inorganic or organic compound in the form of granular or fine particulate solid. The components described hereinabove are supported on the solid carrier. [0213]
Examples of the inorganic compounds and the organic compounds are as described hereinabove, with the porous oxides and the inorganic halides such as inorganic chlorides being preferable. [0214]
The olefin polymerization catalysts of the invention may be prepared as described below. [0215]
In a first embodiment, the olefin polymerization catalysts of the invention may be prepared by adding the components (A), (B) and (C) to an inert hydrocarbon or a polymerization system containing an inert hydrocarbon. [0216]
The components may be added in any order, but are preferably added in exemplary orders as described below.
i) The components are added to a polymerization system in the order of the component (C), the component (A) and the component (B).
ii) The components are added to a polymerization system
in the order of the component (C), the component (B) and the component (A).
iii) The component (A) and the component (C) are mixed and contacted together. The contact product is added to a polymerization system and thereafter the component (B) is added to the polymerization system.
iv) The component (A) and the component (C) are mixed and contacted together. The contact product is added to a polymerization system and thereafter the component (B) is added to the polymerization system.
v) The component (C) is added to a polymerization system. The component (A) and the component (B) are mixed and contacted together, and the contact product is added to the polymerization system.
vi) The components are added to a polymerization system in the order of the component (C), the component (A) and the component (B) . The component (C) is thereafter added again to the polymerization system.
vii) The components are added to a polymerization system in the order of the component (C), the component (B) and the component (A) . The component (C) is thereafter added again to the polymerization system.
viii) The component (A) and the component (C) are mixed and contacted together, and the contact product is added to
a polymerization system. The component (B) is thereafter added to the polymerization system, and the component (C) is added again to the polymerization system.
ix) The component (B) and the component (C) are mixed and contacted together, and the contact product is added to a polymerization system. The component (A) is thereafter added to the polymerization system, and the component (C) is added again to the polymerization system.
x) The component (C) is added to a polymerization system. The component (A) and the component (B) are mixed and contacted together, and the contact product is added to the polymerization system. The component (C) is added again to the polymerization system.
Of these, the addition sequences i), ii) and v) are particularly preferred. [0217]
In a second embodiment, the olefin polymerization catalysts of the invention may be prepared by adding a solid catalyst component (Kl) formed of the solid carrier (S) and the components (C) and (A) , and a solid catalyst component (K2) formed of the solid carrier (S) and the components (C) and (B) to an inert hydrocarbon or a polymerization system containing an inert hydrocarbon. [0218]
The components may be brought into contact in any order, but are preferably contacted in exemplary orders as described below.
xi) The component (C) is contacted with the component (S) and then with the component (A) to form a solid catalyst component (Kl). Separately, the component (C) is contacted with the component (S) and then with the component (B) to form a solid catalyst component (K2) . These catalyst components are used in polymerization.
xii) The component (A) is contacted with the component (C) and then with the component (S) to form a solid catalyst component (Kl) . Separately, the component (B) is contacted with the component (C) and then with the component (S) to form a solid catalyst component (K2) . These catalyst components are used in polymerization.
xiii) The component (C) is contacted with the component (S) and then with a contact product between the component (A) and the component (C) to form a solid catalyst component (Kl) . Separately, the component (C) is contacted with the component (S) and then with a contact product between the component (B) and the component (C) to form a solid catalyst component (K2) . These catalyst components are used in polymerization.
xiv) The component (C) is contacted with the component (S) , then with the component (A) and thereafter again with the
component (C) to form a solid catalyst component (Kl). Separately, the component (C) is contacted with the component (S) , then with the component (B) and thereafter again with the component (C) to form a solid catalyst component (K2) . These catalyst components are used in polymerization.
Of these, the contact sequences xi) and xiii) are particularly preferred. [0219]
In a third embodiment, the olefin polymerization catalysts (K3) of the invention may be prepared by contacting the component (A), the component (B), the component (C) and the solid carrier (S) in an inert hydrocarbon. [0220]
The components may be brought into contact in any order, but are preferably contacted in exemplary orders as described below.
xv) The component (S) is mixed and contacted with the component (C). The contact mixture is brought into contact with the component (A) and then with the component (B).
xvi) The component (S) is mixed and contacted with the component (C). The contact mixture is brought into contact with the component (B) and then with the component (A).
xvii) The component (S) is mixed and contacted with the component (C). The contact mixture is brought into contact
with a contact mixture of the components (A) and (B).
xviii) The component (A) is mixed and contacted with the component (B). The contact mixture is brought into contact with the component (C) and then with the component (S).
xix) The component (S) is contacted with the component (C) . The contact product is brought into contact with the component (C), then with the component (A) and the component
(B) .
xx) The component (S) is contacted with the component (C) . The contact product is brought into contact with the component (C), then with the component (B) and the component (A).
xxi) The component (S) is contacted with the component
(C) . The contact product is brought into contact with the
component (C) and then with a contact mixture of the components
(A) and (B).
xxii) The component (S) is mixed and contacted with the component (C). The contact mixture is brought into contact with a contact mixture of the components (A), (B) and (C).
xxiii) The component (S) is mixed and contacted with the component (C). The contact mixture is brought into contact with a contact mixture of the components (A) and (C) and then with the component (B) .
xxiv) The component (S) is mixed and contacted with the component (C) . The contact mixture is brought into contact
with a contact mixture of the components (B) and (C) and then with the component (A) .
xxv) The component (S) is contacted with the component (C). The contact product is brought into contact with the component (C) , then with a contact mixture of the components
(A) and (C) and with a contact mixture of the components (B)
and (C).
xxvi) The component (S) is contacted with the component (C) . The contact product is brought into contact with the component (C) , then with a contact mixture of the components
(B) and (C) and with a contact mixture of the components (A)
and (C).
xxvii) The component (S) is contacted with the component
(C) . The contact product is brought into contact with the
component (C) and with a contact mixture of the components (A) ,
(B) and (C).
xxviii) A mixture of the components (A) and (C) and a mixture of the components (B) and (C) are mixed together. The mixture is then brought into contact with a contact product of the components (S) and (C).
xxix) A mixture of the components (A) and (C) and a mixture of the components (B) and (C) are mixed together. The mixture is then brought into contact with a contact product obtained by contacting the component (S) and the component (C) and
contacting the resultant contact product with the component (C) .
When a plurality of the components (C) are used, the components (C) may be the same or different from one another. Of these contact sequences, the sequences xv), xvi), xvii), xxii) , xxiii) and xxiv) are preferable, and the sequences xvii) and xxii) are more preferable. [0221]
In the exemplary contact sequences described above, the step (PI) which includes contacting the components (S) and (C) , the step (P2) which includes contacting the components (S) and (A), the step (P3) which includes contacting the components (S) and (B), and the step which includes contacting the components (S), (A) and (B) may be performed in the presence of at least one component (G) selected from polyalkylene oxide blocks (g-1), higher aliphatic amides (g-2), polyalkylene oxides (g-3), polyalkylene oxide alkyl ethers (g-4), alkyl diethanol amines (g-5) and polyoxyalkylene alkylamines (g-6). The presence of the components (G) inhibits the fouling during the polymerization and improves particle properties of the obtainable polymers. Of the components (G), (g-1), (g-2), (g-3) and (g-4) are preferable, and (g-1) and (g-2) are particularly preferable. [0222]
The solvents used in the preparation of the solid catalyst components include inert hydrocarbon solvents, and in detail aliphatic hydrocarbons such as propane, butane, pentane, hexane, heptane, octane, decane, dodecane and kerosine; alicyclic hydrocarbons such as cyclopentane, cyclohexane and methylcyclopentane; aromatic hydrocarbons such as benzene, toluene and xylene; halogenated hydrocarbons such as ethylene chloride, chlorobenzene and dichloromethane; and mixtures of these hydrocarbons. [0223]
When the component (C) and the component (S) are brought into contact together, the reaction site in the component (C) and the reaction site in the component (S) react with each other to form a chemical bond, resulting in a contact product between the component (C) and the component (S). The time of contact of the component (C) and the component (S) is usually in the range of 0 to 20 hours, and preferably 0 to 10 hours . The contact temperature is usually in the range of -50 to 200°C, and preferably -20 to 120°C. If the initial contact between the components (C) and (S) takes place precipitously, the reaction heat or reaction energy breaks the component (S) to cause a deteriorated morphology of the obtainable solid catalyst component. The use of such component in polymerization will result in difficult continuous operation due to bad morphology










I/WE CLAIM:
1. A bridged metallocene compound represented by Formula [1] below:
(Formula Removed)
wherein R1, R2, R3 and R4 are selected from a hydrogen atom, hydrocarbon groups, silicon-containing groups, heteroatom-containing groups and halogen-containing groups and are the same or different from one another; R1, R2, R3 and R4 are not all hydrogen atoms and at least one of these groups is an ethyl group or a group represented by any of Formulae [2] to [7] below; neighboring substituent groups among R1 to R4 may be linked together to form an aliphatic ring; Q1 is selected from Cl-20 hydrocarbon groups, halogen-containing groups, silicon-containing groups, germanium-containing groups and tin-containing groups; X independently at each occurrence is a group selected from a hydrogen atom, halogen atoms, hydrocarbon groups, halogen-containing groups,
silicon-containing groups, oxygen-containing groups, sulfur-containing groups, nitrogen-containing groups and phosphorus-containing groups; and M is a titanium atom, a zirconium atom or a hafnium atom;
(Formula Removed)
wherein R7 to R16 are selected from a hydrogen atom, hydrocarbon groups, silicon-containing groups, heteroatom-containing groups and halogen-containing groups and are the same or different from one another, but they are not aryl groups; D and E are each a divalent heteroatom; G and L are each a trivalent heteroatom; and T and W are each a tetravalent heteroatom or a carbon atom.
2. An olefin polymerization catalyst (a) comprising the following components (A) and (C):
Component (A): the bridged metallocene compound of Formula [1] described in claim 1;
Component (C): at least one compound selected from the group consisting of:
(c-1) organometallic compounds represented by Formulae
[11], [12] and [13] below;
(c-2) organoaluminum oxy-compounds; and
(c-3) compounds that react with the component (A) to form
an ion pair;
(Formula Removed)
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; X is a halogen atom; 0 (Formula Removed)
wherein Ma is Li, Na or K; and Ra is a Cl-15 hydrocarbon group;
(Formula Removed)
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; Mb is selected from Mg, Zn and Cd; X is a halogen atom; 0 3. An olefin polymerization catalyst (b) comprising the following components (A), (B) and (C):
Component (A): the bridged metallocene compound of Formula (1) described in claim 1;
Component (B): a bridged metallocene compound represented by Formula [14] below;
(Formula Removed)
wherein R17 to R20, and R21 to R28 are selected from a hydrogen atom, hydrocarbon groups, halogen-containing groups, oxygen-containing groups, nitrogen-containing groups, boron-containing groups, sulfur-containing groups, phosphorus-containing groups, silicon-containing groups, germanium-containing groups and tin-containing groups and are the same or different from one another; neighboring substituent groups among these groups may be linked together to form a ring; Q2 is selected from Cl-20 hydrocarbon groups, halogen-containing groups, silicon-containing groups, germanium-containing groups and tin-containing groups; M is selected from a titanium atom, a zirconium atom and a hafnium atom; and X independently at each occurrence is a group selected from a hydrogen atom, halogen atoms, hydrocarbon groups,
halogen-containing groups, silicon-containing groups, oxygen-containing groups, sulfur-containing groups, nitrogen-containing groups and phosphorus-containing groups;
Component (C): at least one compound selected from the group consisting of:
(c-1) organometallic compounds represented by Formulae [18], [19] and [20] below;
(c-2) organoaluminum oxy-compounds; and
(c-4) compounds that react with the components (A) and (B) to form an ion pair;
(Formula Removed)
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; X is a halogen atom; 0 (Formula Removed)
wherein Ma is Li, Na or K; and Ra is a Cl-15 hydrocarbon group;
(Formula Removed)
wherein Ra and Rb are each a Cl-15 hydrocarbon group and are the same or different from each other; Mb is selected from Mg, Zn and Cd; X is a halogen atom; 0 + s + t = 2.
4. The olefin polymerization catalyst (b) according to claim 3, which comprises a solid catalyst component (Kl) comprising a solid carrier (S), the component (C) and the component (A), and a solid catalyst component (K2) comprising a solid carrier (S) , the component (C) and the component (B) .
5. The olefin polymerization catalyst (b) according to claim 3, which comprises a solid catalyst component (K3) comprising a solid carrier (S) , the component (A) , the component (B) and the component (C).
6. The olefin polymerization catalyst (b) according to any one of claims 3 to 5, wherein in Formula [1], at least one of R1, R2, R3 and R4 is a hydrocarbon group.
7. The olefin polymerization catalyst (b) according to any one of claims 3 to 5, wherein the component (C) is an organoaluminum oxy-compound (c-2).
8. The olefin polymerization catalyst (b) according to any one of claims 4 to 7, wherein the solid carrier (S) is a porous oxide.
9. A process for producing olefin polymers, comprising polymerizing one or more monomers selected from ethylene and C3-20 olefins in the presence of the olefin polymerization catalyst described in any one of claims 2 to 8, wherein at least one of the monomers is ethylene or propylene.
10. A process for producing ethylene polymers, comprising homopolymerizing ethylene or copolymerizing ethylene and a C3-20 olefin in the presence of the olefin polymerization catalyst described in any one of claims 2 to 8.
11. An ethylene polymer (i) which is obtained by homopolymerizing ethylene or polymerizing ethylene and a C4-20 olefin in the presence of the olefin polymerization catalyst described in any one of claims 3 to 8 and which satisfies the following requirements [1] to [5] at the same time:
[1] the melt flow rate (MFR) as measured at 190°C under a load of 2.16 kg is in the range of 0.1 to 100 g/10 min;
[2] the density (d) is in the range of 875 to 970 kg/m3;
[3] the ratio [MT/* (g/P) ] is in the range of 1.50 x 10"4 to 9.00 x 10-4 wherein [MT (g)] is the melt tension at 190°C and [* (P) ] is the shear viscosity at 200°C and an angular velocity of 1.0 rad/sec;
[4] per 1000 carbon atoms, the total of methyl branches [A (/1000 C) ] and ethyl branches [B (/1000 C) ] , [ (A + B) (/1000 C) ] , is not more than 1.8 according to 13C-NMR;
[5] the zero-shear viscosity at 200°C [0 (P)] and the weight average molecular weight (Mw) measured by GPC-viscometry (GPC-VISCO) satisfy Equation (Eq-1) below:
(Formula Removed)
12. An ethylene polymer (ii) which is obtained by homopolymerizing ethylene or polymerizing ethylene and a C4-20 olefin in the presence of the olefin polymerization catalyst described in any one of claims 3 to 8 and which satisfies the following requirements [1] to [6] at the same time:
[1] the melt flow rate (MFR) as measured at 190°C under a load of 2.16 kg is in the range of 0.1 to 100 g/10 min;
[2] the density (d) is in the range of 875 to 970 kg/m3;
[3] the ratio [MT/TI* (g/P) ] is in the range of 2.50 x 10-4 to 9.00 x 10"4 wherein [MT (g)] is the melt tension at 190°C and [* (P)] is the shear viscosity at 200°C and an angular velocity of 1.0 rad/sec;
[4] per 1000 carbon atoms, the total of methyl branches [A (/1000 C) ] and ethyl branches [B (/1000 C) ] , [ (A + B) (/1000 C) ] , is not more than 1.8 according to 13C-NMR;
[5] the zero-shear viscosity at 200°C [f]0 (P)] and the weight average molecular weight (Mw) measured by GPC-viscometry (GPC-VISCO) satisfy Equation (Eq-1) below:
(Formula Removed)
[6] a molecular weight distribution curve obtained by GPC shows a molecular weight at a maximum weight fraction (peak top M) in the range of 1.0 x 104.30 to 1.0 x 104.50.
13. An ethylene polymer (iii) which is obtained by homopolymerizing ethylene or polymerizing ethylene and a C4-20 olefin in the presence of the olefin polymerization catalyst described in any one of claims 3 to 8 and which satisfies the following requirements [1] to [6] at the same time:
[1] the melt flow rate (MFR) as measured at 190°C under a load of 2.16 kg is in the range of 0.1 to 100 g/10 min;
[2] the density (d) is in the range of 875 to 936 kg/m3;
[3] the ratio [MT/rf (g/P) ] is in the range of 2.50 x 10-4 to 9.00 x 10-4 wherein [MT (g)] is the melt tension at 190°C and [* (P)] is the shear viscosity at 200°C and an angular velocity of 1.0 rad/sec;
[4] per 1000 carbon atoms, the total of methyl branches [A (/1000 C) ] and ethyl branches [B (/1000 C) ] , [ (A + B) (/1000 C)], is not more than 1.8 according to 13C-NMR;
[5] the zero-shear viscosity at 200°C [0 (P) ] and the weight average molecular weight (Mw) measured by GPC-viscometry (GPC-VISCO) satisfy Equation (Eq-1) below:
(Formula Removed)
[6] a molecular weight distribution curve obtained by GPC shows a molecular weight at a maximum weight fraction (peak top M) in the range of 1.0 x 104.20 to 1.0 x 104.50.
14. An ethylene polymer (iv) which is obtained by polymerizing ethylene and a C3-20 olefin in the presence of the olefin polymerization catalyst described in any one of claims 3 to 8 and which satisfies the following requirements [1] to [5] at the same time:
[1] the ratio [M3-4/M3-10] is in the range of 0.30 to 1.00 wherein [M3-4 (mol%) ] is the content of C3-4 α-olefins and [M3-10 (mol%)] is the content of C3-10 a-olefins according to 13C-NMR;
[2] the melt flow rate (MFR) as measured at 190°C under a load of 2.16 kg is in the range of 0.1 to 100 g/10 min;
[3] the density (d) is in the range of 875 to 970 kg/m3;
[4] the ratio [MT/* (g/P) ] is in the range of 1.50 x 10-4 to 9.00 x 10-4 wherein [MT (g)] is the melt tension at 190°C
and [* (P)] is the shear viscosity at 200°C and an angular velocity of 1.0 rad/sec;
[5] the zero-shear viscosity at 200°C [0 (P) ] and the weight average molecular weight (Mw) measured by GPC-viscometry (GPC-VISCO) satisfy Equation (Eq-1) below:
(Formula Removed)
15. A shaped article obtained from the ethylene polymer
described in any one of claims 9 to 14.
16. The shaped article according to claim 15, which is
a film.

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=xwDwiHU/OtUgifSHPvr0uA==&loc=+mN2fYxnTC4l0fUd8W4CAA==


Patent Number 269042
Indian Patent Application Number 3810/DELNP/2010
PG Journal Number 40/2015
Publication Date 02-Oct-2015
Grant Date 29-Sep-2015
Date of Filing 31-May-2010
Name of Patentee MITSUI CHEMICALS, INC.
Applicant Address 5-2, HIGASHI-SHIMBASHI 1-CHOME, MINATO-KU, TOKYO 1057117, JAPAN
Inventors:
# Inventor's Name Inventor's Address
1 SEKIOKA, YUSUKE C/O MITSUI CHEMICALS, INC., 1-2, WAKI 6-CHOME, WAKICHO, KUGA-GUN, YAMAGUCHI 7400061, JAPAN
2 SUZUKI, MASAO C/O PRIME POLYMER CO., LTD., 3, CHIGUSAKAIGAN, ICHIHARA-SHI, CHIBA 2990108, JAPAN
3 TANIFUJI, DAISUKE C/O PRIME POLYMER CO., LTD.,6, TAKASAGO 1-CHOME, TAKAISHI-SHI, OSAKA 5928501, JAPAN
4 BANDO, HIDEKI MITSUI CHEMICALS, INC., 580-32, NAGAURA, SODEGAURA-SHI, CHIBA 2990265, JAPAN
5 SATOH, YASUO C/O PRIME POLYMER CO., LTD., 3, CHIGUSAKAIGAN, ICHIHARA-SHI, CHIBA 990108, JAPAN
6 YUKITA, TAKASHI C/O MITSUI CHEMICALS, INC., 580-32 NAGAURA, SODEGAURA-SHI, CHIBA 2990265, JAPAN
7 HARADA, YASUYUKI C/O MITSUI CHEMICALS, INC., 580-32 NAGAURA, SODEGAURA-SHI, CHIBA 2990265, JAPAN
8 SONOBE, YOSHIHO C/O MITSUI CHEMICALS, INC., 580-32 NAGAURA, SODEGAURA-SHI, CHIBA 2990265, JAPAN
9 TOHI, YASUSHI C/O MITSUI CHEMICALS, INC., 1-2, WAKI 6-CHOME, WAKICHO, KUGA-GUN, YAMAGUCHI 7400061, JAPAN
PCT International Classification Number C07F 17/00
PCT International Application Number PCT/JP2008/071012
PCT International Filing date 2008-11-19
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2007-299202 2007-11-19 Japan
2 2008-015004 2008-01-25 Japan
3 2008-015006 2008-01-25 Japan
4 2007-299203 2007-11-19 Japan
5 2008-015005 2008-01-25 Japan