U.S. patent application number 09/422524 was filed with the patent office on 2001-11-15 for process for preparation of butyl rubber using activated alkylaluminum halides.
Invention is credited to GRONOWSKI, ADAM.
Application Number | 20010041780 09/422524 |
Document ID | / |
Family ID | 4162974 |
Filed Date | 2001-11-15 |
United States Patent
Application |
20010041780 |
Kind Code |
A1 |
GRONOWSKI, ADAM |
November 15, 2001 |
PROCESS FOR PREPARATION OF BUTYL RUBBER USING ACTIVATED
ALKYLALUMINUM HALIDES
Abstract
A process for preparing a butyl polymer having a weight average
molecular weight of at least about 400,000. The process comprises
the step of contacting a C.sub.4 to C.sub.8 monoolefin monomers
with a C.sub.4 to C.sub.14 multiolefin monomer at a temperature in
the range of from about -100.degree. C. to about +50.degree. C. in
the presence of an aliphatic hydrocarbon diluent and a catalyst
mixture comprising a major amount of a dialkylalumium halide, a
minor amount of a monoalkylaluminum dihalide, and a minute amount
of at least one of a member selected from the group comprising
water, aluminoxane and mixtures thereof.
Inventors: |
GRONOWSKI, ADAM; (ONTARIO,
CA) |
Correspondence
Address: |
PATENT DEPARTMENT
BAYER CORPORATION
100 BAYER ROAD
PITTSBURGH
PA
152059741
|
Family ID: |
4162974 |
Appl. No.: |
09/422524 |
Filed: |
October 21, 1999 |
Current U.S.
Class: |
526/226 ;
526/348.2; 526/348.5; 526/348.6 |
Current CPC
Class: |
C08F 210/12 20130101;
C08F 210/12 20130101; C08F 4/52 20130101; C08F 210/12 20130101;
C08F 236/08 20130101; C08F 2500/03 20130101 |
Class at
Publication: |
526/226 ;
526/348.2; 526/348.5; 526/348.6 |
International
Class: |
C08F 210/04 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 30, 1998 |
CA |
2252295 |
Claims
What is claimed is:
1. A process for preparing a butyl polymer having a weight average
molecular weight of at least about 400,000, the process comprising
the step of: contacting a C.sub.4 to C.sub.8 monoolefin monomers
with a C.sub.4 to C.sub.14 multiolefin monomer at a temperature in
the range of from about -100.degree. C. to about +50.degree. C. in
the presence of an aliphatic hydrocarbon diluent and a catalyst
mixture comprising a major amount of a dialkylalumium halide, a
minor amount of a monoalkylaluminum dihalide, and a minute amount
of at least one of a member selected from the group comprising
water, aluminoxane and mixtures thereof.
2. The process defined in claim 1, wherein said catalyst mixture
contains from about 80 to about 99 mol percent of the
dialkylaluminum halide and from about 1 to about 20 mol percent of
the monoalkylaluminum dihalide, and when the amount of water added
to the catalyst solution is such that the total water content in
the reaction feed is from 2 to 100 ppm.
3. The process defined in claim 1, wherein said catalyst mixture
contains from about 80 to about 99 mol percent of the
dialkylaluminum halide and from about 1 to about 20 mol percent of
the monoalkylaluminum dihalide, and wherein the amount of
aluminoxane added to the catalyst solution is such that the content
of aluminoxane in the reaction feed is from 0.01 to 10 ppm.
4. The process defined in claim 2, wherein water is added directly
to the catalyst solution and the resulting solution containing
suspended white particles is used directly to initiate
polymerization reactions.
5. The process defined in claim 3, wherein aluminoxane is added
directly to the catalyst solution and the resulting homogenous
solution is used directly to initiate polymerization reactions.
6. The process defined in claim 1, wherein the diluent is a C.sub.4
to C.sub.8 saturated aliphatic hydrocarbon.
7. The process defined in claim 1, wherein the C.sub.4 to C.sub.8
monoolefin is an isomonoolefin.
8. The process defined in claim 1, wherein the C.sub.4 to C.sub.14
multiolefin is a C.sub.4 to C.sub.10 conjugated diolefin.
9. The process defined in claim 1, wherein from about 0.01 to about
2.0 wt. percent of the dialkylaluminum halide is employed, based on
the total of said monomers present.
10. The process defined in claim 1, wherein from about 0.002 to
about 0.4 wt. percent of the monoalkylaluminum dihalide is
employed, based on the total of said monomers present.
11. The process defined in claim 1, wherein the amount of water in
the reaction feed is from 2 to 100 ppm.
12. The process defined in claim 1, wherein the amount of
aluminoxane in the reaction feed is from 0.01 to 10 ppm.
13. The process defined in claim 1, wherein the temperature is in
the range of from about B80.degree. C. to about B20.degree. C.
14. A process for producing a solution butyl rubber polymer having
a weight average molecular weight of at least about 400,000, the
process comprising the step of: reacting a C.sub.4 to C.sub.8
isomonoolefin with a C.sub.4 to C.sub.10 conjugated diolefin at a
temperature in the range of from about about B80.degree. C. to
B20.degree. C. in the presence of a C.sub.4 to C.sub.8 paraffinic
diluent and a catalyst mixture comprising: (i) from about 85 to
about 99 mol percent of a C.sub.2 to C.sub.16 dialkylaluminum
halide component wherein each alkyl group contains from 1 to 8
carbon atoms; (ii) from about 1 to about 15 mol percent of a
C.sub.1 to C.sub.8 monoalkylaluminum dihalide component wherein
each alkyl group contains from 1 to 8 carbon atoms, and (iii) water
in an amount of from about 2 to about 100 ppm of the total reaction
feed.
15. A process for producing a solution butyl rubber polymer having
a weight average molecular weight of at least about 400,000, the
process comprising the step of: reacting a C.sub.4 to C.sub.8
isomonoolefin with a C.sub.4 to C.sub.10 conjugated diolefin at a
temperature in the range of from about about B80.degree. C. to
B20.degree. C. in the presence of a C.sub.4 to C.sub.8 paraffinic
diluent and a catalyst mixture comprising: (i) from about 85 to
about 99 mol percent of a C.sub.2 to C.sub.16 dialkylaluminum
halide component wherein each alkyl group contains from 1 to 8
carbon atoms; (ii) from about 1 to about 15 mol percent of a
C.sub.1 to C.sub.8 monoalkylaluminum dihalide component wherein
each alkyl group contains from 1 to 8 carbon atoms, and (iii) an
aluminoxane in an amount of from about 0.01 to about 10 ppm of the
total reaction feed.
16. The process defined in claim 14, wherein the dialkylaluminum
halide is a C.sub.2 to C.sub.8 dialkylaluminum chloride wherein
each alkyl group contains from 1 to 4 carbon atoms.
17. The process defined in claim 15, wherein the dialkylaluminum
halide is a C.sub.2 to C.sub.8 dialkylaluminum chloride wherein
each alkyl group contains from 1 to 4 carbon atoms.
18. The process defined in claim 14, wherein the monoalkylaluminum
halide is a C.sub.1 to C.sub.4 alkylaluminum dichloride.
19. The process defined in claim 15, wherein the monoalkylaluminum
halide is a C.sub.1 to C.sub.4 alkylaluminum dichloride.
20. The process defined in claim 15, wherein the aluminoxane is
methylaluminoxane.
Description
TECHNICAL FIELD
[0001] In one of its aspects, the present invention relates to an
improved, catalytic, solution process for preparing butyl rubber
polymers. More particularly, the present invention relates to such
a process for preparing butyl rubber polymers with good isobutylene
conversions, such polymers having weight average molecular weights
of greater than 400,000 at polymerization temperatures of
-100.degree. C. to +50.degree. C. in a readily controlled process
enabling the use of low cost, inert, aliphatic hydrocarbon
solvents.
BACKGROUND ART
[0002] Almost all world production of butyl rubber utilizes methyl
chloride as a diluent. Methyl chloride is not an ozone depleter and
only a very small fraction of it occurring in the environment is
the result of industrial processes. However, exposure to methyl
chloride can cause injury to liver, kidneys and the central nervous
system. The growing health concerns regarding methyl chloride
stimulated the search for an alternative reaction medium in the
process of manufacturing butyl rubber.
[0003] A process for manufacturing butyl rubber in a hydrocarbon
solvent (e.g., hexane) is also useful in the preparation of
halobutyl rubber since it eliminates the dissolving step and thus
simplifies the whole halobutyl process.
[0004] Conventional prior art processes for preparing butyl rubber
polymers in solution (solution butyl processes) chiefly employ
aluminum trihalide catalyst systems, viz, those using aluminum
trichloride, or aluminum tribrommide alone. For example see U.S.
Pat. No. 2,844,569 and 2,772,255. These prior art procedures are
not wholly satisfactory because they are performed at very low
temperatures, e.g. -90.degree. C. to -110.degree. C. leading to
high refrigeration costs during polymerization. At such low
temperatures, polymer solutions have a very high viscosity and are
difficult to handle. In addition, a high viscosity of a polymer
solution causes a very low rate of heat transfer, and also poor and
difficult catalyst dispersion.
[0005] Aluminum trichloride has the disadvantage of little or no
solubility in many desirable hydrocarbon systems and is often
introduced to the reaction feed as a solution in methyl chloride.
Although aluminum tribromide is soluble in hydrocarbons, the use
thereof can cause the undersirable formation of substantial amounts
of very high molecular weight fractions--see U.S. Pat. No.
2,772,255 [Ernst et. al.].
[0006] Alkylaluminum dihalides are generally less reactive than the
aluminum halides but offer the advantage of excellent hydrocarbon
solubility. To enhance their reactivity, they are frequently used
together with cocatalysts.
[0007] Canadian patent 1,019,095 [Scherbakova et al. (Scherbakova)]
teaches an industrial process for manufacturing butyl rubber in
solution. The catalyst system used in the process comprises an
alkylaluminum halide (e.g., ethylaluminum sesquichloride
((C.sub.2H.sub.5).sub.2AlCl.Cl.sub.2A- lC.sub.2H.sub.5)), with
water or hydrogen sulfide as a co-catalyst, and isopentane as a
solvent. Not many details are known about the process, which most
probably takes place at -85.degree. C. to -80.degree. C., with a
content of solids in solution at about 10 weight percent. Some of
the drawbacks of this method are listed below.
[0008] A direct reaction between water and the Lewis acid is not
possible due to a violent nature of this reaction and a substantial
amount of water used per alkylaluminum halide. Hence, preparation
of the catalyst species is a cumbersome step in the whole process
and it can take several hours. Two ways of performing this are
taught in Scherbakova.
[0009] One approach to prepare the catalyst is to introduce water
into the solution of the alkylaluminum halide in a hydrocarbon
solvent together with an inert gas which is circulated in the
system "alkylaluminum halide solution--water" and is continuously
saturated with water.
[0010] The alternative method is to introduce water into the
solution of the alkylaluminum halide in a hydrocarbon solvent as
part of crystal hydrates of mineral salts, e.g.,
CuSO.sub.4.5H.sub.2O. The reactions are then not as violent than
when water is introduced directly.
[0011] In the hydrolysis reactions higher alkylaluminoxanes are
formed, which are filtered out and the clear solution is used to
initiate the polymerizations. This represents an additional
complicating step in the whole procedure to prepare the active
initiating species.
[0012] A disadvantage of the both above catalyst preparation
methods, beside long duration, is that the activity of the catalyst
changes with time as the hydrolysis progresses. This requires the
use of analytical methods to monitor the progress of the
hydrolysis. This is not a simple task since alkylaluminum compounds
require a special careful analytical treatment.
[0013] U.S. Pat. No. 3,361,725 [Parker et al. (Parker)] teaches
that mixtures of dialkylaluminum halides, e.g., dialkylaluminum
chlorides, and monoalkylaluminum dihalides, e.g., monoalkylaluminum
dichlorides (in which a latter component is present in small
amounts) are effective solution butyl rubber catalysts, operate at
the far more economical (higher) temperatures and form excellent
high molecular weight rubbers. Usually, the butyl rubber
polymerizations using the above catalyst mixtures are conducted at
temperatures ranging from about -87.degree. C. to -57.degree. C.,
and preferably at temperatures of -79.degree. C. to -68.degree. C.,
with excellent results being achieved with temperatures at or near
-73.degree. C. at approximately atmospheric pressure.
[0014] The polymers are soluble in the unreacted monomers as well,
so that relatively minor amounts of diluent can be used. Reasonably
small quantities of diluent can be employed--e.g., from 0 to 50
vol. percent diluent based on total volume of monomer and saturated
catalyst solvent. Usually, however, the concentration of diluent
during polymerization ranges from 0 to 20 vol. percent. The ability
to use small concentrations of diluent during polymerization
constitutes an economic advantage. The diluents usually employed to
conduct the solution butyl polymerization reactions are C.sub.5 to
C.sub.6 normal, iso, and cyclo paraffinic hydrocarbons which are
liquids at the reaction temperatures and pressures employed.
Preferably the C.sub.5 and C.sub.6 normal paraffins are used--e.g.,
n-pentane and n-hexane.
[0015] The catalyst mixture consists of from about 2 to about 10
mole percent of the monoalkylaluminum dihalide and from about 90 to
98 mole percent of the dialkylaluminum monohalide. This facilitates
achievement of the most advantageous combination of ease of
polymerization coupled with catalyst efficiency and good
temperature control over the polymerization reaction. This latter
characteristic is a significant advantage of the method. On the
other hand, the reaction times require from about 50 to 100 minutes
within the preferred temperature range.
[0016] It would be useful to have a method allowing good
temperature control to be maintained during polymerizations but
with higher reaction rates and higher molecular weight rubber
formed than with the use of the catalyst taught by Parker. This
should make it possible to carry out polymerizations even at more
economical (higher) temperatures than with the method taught by
Parker, with the rubber still displaying desirable properties.
DISCLOSURE OF THE INVENTION
[0017] It is the object of the present invention to provide an
improved method to manufacture solution butyl rubber.
[0018] Accordingly, the present process provides a process for
preparing a butyl polymer having a weight average molecular weight
of at least about 400,000, the process comprising the step of:
[0019] contacting a C.sub.4 to C.sub.8 monoolefin monomers with a
C.sub.4 to C.sub.14 multiolefin monomer at a temperature in the
range of from about -100.degree. C. to about +50.degree. C. in the
presence of an aliphatic hydrocarbon diluent and a catalyst mixture
comprising a major amount of a dialkylalumium halide, a minor
amount of a monoalkylaluminum dihalide, and a minute amount of at
least one of a member selected from the group comprising water,
aluminoxane and mixtures thereof.
[0020] More specifically, the present invention is directed to the
preparation of butyl rubber polymers having weight average
molecular weights greater than 400,000 by reacting a C.sub.4 to
C.sub.8 olefin monomer, preferably a C.sub.4 to C.sub.8
isomonoolefin with a C.sub.4 to C.sub.14 multiolefin monomer,
preferably a C.sub.4 to C.sub.10 conjugated diolefin monomer, at
temperatures ranging from -100.degree. C. to +50.degree. C.,
preferably from -80.degree. C. to -20.degree. C., in the presence
of an aliphatic hydrocarbon diluent in which said polymers are
soluble and a catalyst mixture comprising: (A) a major amount,
e.g., 0.01 to 2.0 wt. percent of a dialkylaluminum halide, (B) a
minor amount, e.g., 0.002 to 0.4 wt. percent of a monoalkylaluminum
dihalide (the weight percent being based on the total of the
polymerizable monomers present) with the monoalkylaluminum dihalide
always representing no more than about 20 mole percent of the
catalyst mixture (based on monohalide plus dihalide) and (C) minute
amounts of water or aluminoxane purposely added to activate the
catalyst.
BEST MODE FOR CARRYING OUT THE INVENTION
[0021] The present invention represents an improvement over the
Parker process. The improvement comprises including in the catalyst
mixture minute amounts of water or aluminoxane. This leads to
higher reaction rates, higher molecular weights and also higher
isoprene content in the rubber while maintaining a good temperature
control over the polymerization reactions.
[0022] Thus, an aspect of the present process is based on employing
a modified catalyst system, where the catalyst such as the one
taught by Parker is activated by addition of minute amounts of
water or aluminoxane directly to the catalyst solution. This leads
to higher reaction rates, higher molecular weights and surprisingly
also to higher isoprene content in the rubber while maintaining a
good temperature control over the polymerization reactions.
[0023] As mentioned hereinabove, the present process relates to the
preparation of butyl rubber polymers. The term "butyl rubber" as
used throughout this specification is intended to denote polymers
prepared by reacting a major portion, e.g., from about 70 to 99.5
parts by weight, usually 85 to 99.5 parts by weight of an
isomonoolefin, such as isobutylene, with a minor portion, e.g.,
about 30 to 0.5 parts by weight, usually 15 to 0.5 parts by weight,
of a multiolefin, e.g., a conjugated diolefin, such as isoprene or
butadiene, for each 100 weight parts of these monomers reacted. The
isoolefin, in general, is a C.sub.4 to C.sub.8 compound , e.g.,
isobutylene, 2-methyl-1-butene, 3-methyl-1-butene,
2-methyl-2-butene, and 4-methyl-1-pentene.
[0024] Suitable aliphatic hydrocarbon diluents which can be used in
accordance with the present process include, but are not limited
to, the following: C.sub.4 to C.sub.8 saturated aliphatic and
alicyclic hydrocarbons, such as pentane, hexane, heptane,
isooctane, methylcyclohexane, cyclohexane, etc. Preferably the
C.sub.5 to C.sub.6 normal paraffins are used, e.g., n-pentane and
n-hexane. The same saturated hydrocarbons serve as "solvent" for
the catalyst mixture. The concentration of diluent during
polymerization may range from 0 to about 50 volume percent, and
more preferably from 0 to about 25 volume percent.
[0025] The catalyst mixture used in the present process comprises a
mixture of from about 1 to about 20 mole percent of a
monoalkylaluminum dihalide, from about 80 to to about 99 mole
percent of a dialkylaluminum monohalide and minute amounts of water
or aluminoxane. Usually the catalyst mixture will contain from
about 1 to about 15 mole percent of the monoalkylaluminum dihalide
and from about 85 to about 99 mole percent of the dialkylaluminum
monohalide. Preferably, however, and in order to achieve the most
advantageous combination of ease of polymerization coupled with
catalyst efficiency and good temperature control over the
polymerization reaction the catalyst mixture contains from about 2
to about 10 mole percent of the monoalkylaluminum dihalide and from
about 90 to 98 mole percent of the dialkylaluminum monohalide.
[0026] Usually the dialkylaluminum monohalide employed in
accordance with this invention will be a C.sub.2 to C.sub.16 low
molecular weight dialkylaluminum monochloride, wherein each alkyl
group contains from 1 to 8 carbon atoms. Preferably, C.sub.2 to
C.sub.8 dialkylaluminum chlorides are used, wherein each alkyl
group contains from 1 to 4 carbon atoms. Suitable exemplary
preferred dialkylaluminum monochlorides which can be used in
accordance with this invention include, but are not limited to, a
member selected from the group comprising dimethylaluminum
chloride, diethylaluminum chloride, di(n-propyl)aluminum chloride,
diisopropylaluminum chloride, di(nbutyl)aluminum chloride,
diisobutylaluminum chloride, or any of the other homologous
compounds.
[0027] The monoalkylaluminum dihalides employed in accordance with
the present process may be selected from the C.sub.1 to C.sub.8
monoalkylaluminum dihalides, and preferably are C.sub.1 to C.sub.4
monoalkylaluminum dihalides containing essentially the same alkyl
groups as mentioned hereinabove in conjunction with the description
of the dialkylaluminum monochlorides. Suitable exemplary preferred
C.sub.1 to C.sub.4 monoalkylaluminum dihalides which can be
employed satisfactorily in accordance with the present process
include, but are not limited to, the following: methylaluminum
dichloride, ethylaluminum dichloride, propylaluminum dichlorides,
butylaluminum dichlorides, isobutylaluminum dichloride, etc.
[0028] An important feature of the present invention is that water
is added directly to the catalyst mixture and the resulting
heterogeneous solution is immediately used to start the
polymerization reaction. Preferably, the molar ratio of
alkylaluminum halides to water is from about 4:1 to about 30:1,
more preferably from about 7:1 to about 12:1. When the amount of
water used is in the preferred range, a direct reaction between
water and a Lewis acid can take place (at least in the lab scale),
unlike in the Scherbakova method where cumbersome and lengthy
special treatment is required. This is possible because the amount
of water used in the present process is about 10 times lower than
in the Scherbakova method. Another feature distinguishing the
present invention from the Scherbakova method is that, in the
present process, a heterogeneous solution resulting from adding
water to the Lewis acid is used while in the Scherbakova method, a
filtration step is used and only the soluble portion from the
catalyst solution is employed to initiate the reaction. Thus, the
nature and activity of the initiating species resulting from the
present invention and from the Scherbakova method most probably are
different since it is known that the composition and the catalytic
activity of the species resulting from reaction of water and
alkylaluminum compounds depends on the preparation method and
aging.
[0029] Alternatively, to increase the activity of the Parker
catalyst, minute amounts of aluminoxanes are added instead of
water. The aluminoxane component useful as a catalyst activator
typically is an oligomeric aluminum compound represented by the
general formula (R.sup.2--Al--O).sub.n, which is a cyclic compound,
or R.sup.2(R.sup.2--Al--O).sub.n,AlR.sup.2.sub.2, which is a linear
compound. In the general aluminoxane formula, R.sup.2 is
independently a C.sub.1 to C.sub.10 hydrocarbyl radical (for
example, methyl, ethyl, propyl, butyl or pentyl) and n is an
integer of from 1 to about 100. R.sup.2 may also be, independently,
halogen, including fluorine, chlorine and iodine, and other
non-hydrocarbyl monovalent ligands such as amide, alkoxide and the
like, provided that not more than 25 mol % of R.sup.2 are
non-hydrocarbyl as described here. Most preferably, R.sup.2 is
methyl and n is at least 4.
[0030] Aluminoxanes can be prepared by various procedures known in
the art. For example, an aluminum alkyl may be treated with water
dissolved in an inert organic solvent, or it may be contacted with
a hydrated salt, such as hydrated copper sulfate suspended in an
inert organic solvent, to yield an aluminoxane. Generally, however
prepared, the reaction of an aluminum alkyl with a limited amount
of water yields a mixture of the linear and cyclic species, and
also there is a possibility of interchain complexation
(crosslinking). The catalytic efficiency of aluminoxanes is
dependent not only on a given preparative procedure but also on a
deterioration in the catalytic activity ("aging") upon storage,
unless appropriately stabilized. Methylaluminoxane and modified
methylaluminoxanes are preferred. For further descriptions, see,
for example, one or more of the following U.S. Pat. Nos.
[0031] 4,665,208 4,952,540 5,041,584
[0032] 5,091,352 5,206,199 5,204,419
[0033] 4,874,734 4,924,018 4,908,463
[0034] 4,968,827 5,329,032 5,248,801
[0035] 5,235,081 5,157,137 5,103,031
[0036] the contents of each of which are hereby incorporated by
reference. In the present invention, it is preferred that
aluminoxane is added to the catalyst solution in such an amount
that the reaction feed contains from about 0.01 to about 10 ppm,
preferably from about 0.02 to about 4 ppm.
[0037] The application of the present process results in higher
polymerization rates, higher molecular weights of the rubber (in
particular, especially important weight average molecular weight)
and higher isoprene content in the rubber. It has been unexpectedly
observed that, when aluminoxanes are present in the reaction feed
containing isobutylene, both the polymerization rates and the
molecular weights of the resulting rubber will be higher. For
example, the Russian patent SU 494,391 teaches that when
aluminoxane is used as the catalyst in the polymerization of
isobutylene in a hydrocarbon solvent, higher molecular weights are
achieved but polymerization rates are lower than in the known art.
On the other hand, in U.S. Pat. No. 5,527,870 [Langstein et al.],
it is taught that, when the initiating system is composed of a
functionalized hydrocarbon like methyl chloride or chloroethane
plus aluminoxane, the polymerization of isobutylene in hydrocarbon
solvents leads to higher molecular weights than those of the prior
art at simultaneously elevated rates of conversion. It is a
surprising result of the present invention that the amount of
isoprene incorporated in the rubber is higher while polymerization
rates are also higher and the polymer possesses higher molecular
weights. Usually, in order to incorporate more isoprene in butyl
rubber, more isoprene is needed in the reaction feed which results
in lower reaction rates and lower molecular weights of the product.
This is because in the copolymerization of isobutylene and
isoprene, the diolefin dominates the chain breaking process (J.
Pol. Sci. A, 27, (1989), 107-124). The above-mentioned combination
of higher reaction rates, higher molecular weights, and higher
isoprene content in the rubber achieved in the present process
results in a very desirable scenario from the industrial point of
view, especially when the temperature control over polymerization
reactions remains good. This can allow to synthesize butyl rubber
at more economical (higher) polymerization temperatures than using
the conventional Parker catalyst.
[0038] Embodiments of the present invention will be illustrated
with reference to the following Examples, which should not be use
to construe or limit the scope of the present invention.
EXAMPLE 1
[0039] To a 50 mL Erlenmeyer flask, 3.75 mL of distilled hexane,
4.62 mL Et.sub.2AlCl (1.0 M solution in hexanes) and 0.38 mL
EtAlCl.sub.2 (1.0 M solution in hexanes) were added at room
temperature forming a catalyst solution.
[0040] To a 250 mL 3-neck reaction flask equipped with an overhead
stirrer, 40 mL of isobutylene at -75.degree. C. were added,
followed by 8.0 mL hexane at room temperature and 1.2 mL isoprene
at room temperature. The reaction mixture was cooled down to
-75.degree. C. and 1.8 mL of the catalyst solution was added to
start the reaction.
[0041] The reaction was carried out in MBRAUN.TM. dry box under the
atmosphere of dry nitrogen. The temperature changes during the
reaction were followed by a thermocouple. After 20 minutes, the
reaction was terminated by adding 5 mL of ethanol into the reaction
mixture.
[0042] The polymer solution was poured on an aluminum tare lined
with Teflon and the solvent and unreacted monomers were allowed to
evaporate in a vacuum oven at 70.degree. C.
[0043] The gravimetrically determined yield was 8.4 wt. percent,
M.sub.n=170,100, M.sub.w=394,300, and isoprene content was 1.6 mol
percent.
[0044] This example represents the conventional Parker method and
is provided for comparitive purposes only.
EXAMPLE 2
[0045] The methodology of Example 1 was repeated except 10 .mu.l of
water was added directly to the catalyst solution. After stirring,
1.8 mL of this solution containing suspended white particles was
immediately used to start the reaction.
[0046] The polymer yield was 38.0 wt. percent, M.sub.n=185,000,
M.sub.w=585, 700 and isoprene content in the rubber was 1.9 mol
percent.
EXAMPLE 3
[0047] The methodology of Example 1 was repeated except 15 .mu.l of
water was added directly to the catalyst solution. After stirring,
1.8 mL of this solution containing suspended white particles was
immediately used to start the reaction.
[0048] The polymer yield was 53.4 wt. percent, M.sub.n=121,000,
M.sub.w=514, 100 and isoprene content in the rubber was 2.1 mol
percent.
EXAMPLE 4
[0049] The methodology of Example 1 was repeated except 100 .mu.l
of methylaluminoxane (10 wt. percent solution in toluene) was added
directly to the catalyst solution. After stirring, 1.8 mL of this
homogeneous solution was immediately used to start the
reaction.
[0050] The polymer yield was 37.4 wt. percent, M.sub.n=159,900,
M.sub.w=551, 100 and isoprene content in the rubber was 2.2 mol
percent.
EXAMPLE 5
[0051] To a 50 mL Erlenmeyer flask, 3.75 mL hexane, 4.62 mL
Et.sub.2AlCl (1.0 M solution in hexanes) and 0.38 mL EtAlCl.sub.2
(1.0 M solution in hexanes) were added at room temperature forming
a catalyst solution.
[0052] To a 250 mL 3-neck reaction flask equipped with an overhead
stirrer, 40 mL of isobutylene at -60.degree. C. were added,
followed by 8.0 mL hexane at room temperature and 1.2 mL isoprene
at room temperature. The reaction mixture was cooled down to
-60.degree. C. and 1.0 mL of the catalyst solution was added to
start the reaction.
[0053] The reaction was carried out in MBRAUN.TM. dry box under the
atmosphere of dry nitrogen. The temperature changes during the
reaction were followed by a thermocouple. After 40 minutes, the
reaction was terminated by adding 5 mL of ethanol into the reaction
mixture.
[0054] The polymer solution was poured on an aluminum tare lined
with Teflon and the solvent and unreacted monomers were allowed to
evaporate in a vacuum oven at 70.degree. C.
[0055] The gravimetrically determined yield was 12.5 wt. percent,
M.sub.n=184, 900, M.sub.w=385,100, and isoprene content was 1.6 mol
percent.
[0056] This example represents the conventional Parker method and
is provided for comparitive purposes only.
EXAMPLE 6
[0057] The methodology of Example 5 was repeated except 10 .mu.l of
water was added directly to the catalyst solution. After stirring,
1.0 mL of this solution containing suspended white particles was
immediately used to start the reaction.
[0058] The polymer yield was 26.1 wt. percent, M.sub.n=197,600,
M.sub.w=468, 200 and isoprene content in the rubber was 1.9 mol
percent.
EXAMPLE 7
[0059] The methodology of Example 5 was repeated except 175 .mu.l
of methylaluminoxane (10 wt. percent solution in toluene) was added
directly to the catalyst solution. After stirring, 1.0 mL of this
homogeneous solution was immediately used to start the
reaction.
[0060] The polymer yield was 19.7 wt. percent, M.sub.n=203,000,
M.sub.w=550, 400 and isoprene content in the rubber was 2.3 mol
percent.
[0061] The temperature control in all above reactions was good.
* * * * *