U.S. patent application number 11/216805 was filed with the patent office on 2006-01-05 for films comprising isotactic propylene copolymers.
Invention is credited to Clive Bosnyak, Pak-Wing S. Chum, Seema Karande, Li-Min Tau.
Application Number | 20060004167 11/216805 |
Document ID | / |
Family ID | 23326539 |
Filed Date | 2006-01-05 |
United States Patent
Application |
20060004167 |
Kind Code |
A1 |
Tau; Li-Min ; et
al. |
January 5, 2006 |
Films comprising isotactic propylene copolymers
Abstract
Films with excellent machine direction (MD) tear properties
comprise at least one layer made from a polymer comprising: (A) at
least 50 weight percent (wt %) propylene; and (B) at least 5 wt %
ethylene and/or one or more unsaturated comonomers. Representative
of component (B) unsatuarated comonomers are the C.sub.4-20
.alpha.-olefins, C.sub.4-20 dienes, styrenic compounds, and the
like. Preferably, the film has at least one of a (i) haze value of
less than about 10, (ii) 45 degree gloss of greater than about 65,
and (iii) dart value of greater than about 100 g/mil. In one
preferred embodiment, the layer comprises a compolymer
characterized as having at least one of the following properties:
(i) .sup.13C NMR peaks corresponding to a regio-error at about 14.6
and about 15.7 ppm, the peaks of about equal intensity, (ii) a
B-value greater than about 1.4 when the comonomer content, i.e.,
the units derived from ethylene and/or the unsaturated
comonomer(s), of the copolymer is at least about 3 wt %, (iii) a
skewness index, S.sub.ix, greater than about -1.20, (iv) a DSC
curve with a T.sub.me that remains essentially the same and a
T.sub.max that decreases as the amount of comonomer, i.e., the
units derived from ethylene and/or the unsaturated comonomer(s), in
the copolymer is increased, and (v) an X-ray diffraction pattern
that reports more gamma-form crystals than a comparable copolymer
prepared with a Ziegler-Natta (Z-N) catalyst.
Inventors: |
Tau; Li-Min; (Lake Jackson,
TX) ; Chum; Pak-Wing S.; (Lake Jackson, TX) ;
Karande; Seema; (Pearland, TX) ; Bosnyak; Clive;
(Missouri City, TX) |
Correspondence
Address: |
WHYTE HIRSCHBOECK DUDEK S.C.
555 EAST WELLS STREET
SUITE 1900
MILWAUKEE
WI
53202
US
|
Family ID: |
23326539 |
Appl. No.: |
11/216805 |
Filed: |
August 31, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10289168 |
Nov 5, 2002 |
|
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11216805 |
Aug 31, 2005 |
|
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60338881 |
Nov 6, 2001 |
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Current U.S.
Class: |
526/348.1 ;
526/348.2; 526/348.5; 526/348.6 |
Current CPC
Class: |
C08F 4/6592 20130101;
C08F 4/65912 20130101; C08F 4/65916 20130101; C08J 2367/02
20130101; C09K 2200/0617 20130101; C08F 10/00 20130101; C08F 110/06
20130101; C08L 23/147 20130101; C08L 101/00 20130101; D01F 6/06
20130101; C08F 210/16 20130101; C08J 2323/14 20130101; C08F 210/06
20130101; C08F 110/06 20130101; D01F 6/46 20130101; C09K 3/10
20130101; C09K 2200/062 20130101; C08F 2500/20 20130101; C08F
4/65927 20130101; C08F 2500/15 20130101; C08F 2/001 20130101; C08F
2500/26 20130101; C08F 2500/24 20130101; C08F 2500/15 20130101;
C08F 2500/12 20130101; C08F 2500/20 20130101; C08F 210/16 20130101;
C08L 2666/06 20130101; C08F 2500/12 20130101; C08F 4/64144
20130101; C08L 2666/04 20130101; C08L 2666/06 20130101; C08F
4/65904 20130101; C08F 4/659 20130101; C08F 2500/03 20130101; C08F
2500/12 20130101; C08F 2500/24 20130101; C08F 2500/08 20130101;
C08F 2500/20 20130101; C08L 2666/04 20130101; C08L 23/02 20130101;
B32B 27/32 20130101; C08F 4/65908 20130101; C08L 23/12 20130101;
C07F 7/00 20130101; D01F 6/30 20130101; C08L 23/142 20130101; C08L
23/142 20130101; C08L 2666/04 20130101; C08L 23/10 20130101; C08J
5/18 20130101; C08L 23/147 20130101; C08L 23/10 20130101; C08L
2314/06 20130101; C08F 110/06 20130101; C08L 23/142 20130101; C08J
2323/12 20130101; C08F 210/06 20130101; C08F 110/06 20130101; Y10T
428/31909 20150401; C08F 10/00 20130101; C08F 110/06 20130101; C07B
2200/11 20130101; C08L 2205/02 20130101; C08L 23/12 20130101; C08L
23/16 20130101; C08F 110/06 20130101 |
Class at
Publication: |
526/348.1 ;
526/348.2; 526/348.5; 526/348.6 |
International
Class: |
C08F 10/00 20060101
C08F010/00 |
Claims
1. A film comprising a first layer, the first layer comprising a
first polymer, the first polymer comprising at least about: (a) 50
weight percent propylene, and (b) 5 weight percent ethylene; the
first layer characterized as having a: (1) Machine direction tear
of at least about 100 g/mil, (2) Haze value of less than about 10
percent, (3) 45.degree. Gloss greater than about 65 percent, and
(4) Dart value greater than about 200 g.
2. The film of claim 1 in which the machine direction tear of the
first layer is at least about 125 g/mil.
3. The film of claim 2 in which the first layer has a haze value of
less than about 9 percent.
4. The film of claim 3 in which the first layer has a 45.degree.
gloss greater than about 70 percent.
5. The film of claim 4 in which the first layer has a dart value
greater than about 250 g/mil
6. The film of claim 1 in which the machine direction tear of the
first layer is greater than about 300 g/mil.
7. The film of claim 6 in which the haze value of the first layer
is less than about 6 percent.
8. The film of claim 7 in which the 45.degree. gloss of the first
layer is less than about 80 percent.
9. The film of claim 8 in which the dart value of the first layer
is greater than about 300 g/mil.
10. The film of claim 1 prepared by a blow molding process.
11. The film of claim 10 in which the blow molding process includes
a water-quench of the film.
12. The film of claim 1 comprising a second layer.
13. The film of claim 12 in which the composition of the second
layer is different than the composition of the first layer.
14. A film of claim 13 in which the second layer comprises an
.alpha.-olefin homopolymer or copolymer.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Ser. No.
10/289,168, filed Nov. 5, 2002, which also claims the benefit of
U.S. provisional application Ser. No. 60/338,881 filed Nov. 6,
2001, the disclosures of which are incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] This invention relates to films comprising polypropylene. In
one aspect, the invention relates to films comprising isotactic
copolymers of propylene and at least one of ethylene and an
unsaturated comonomer while in another aspect, the invention
relates to films comprising polymer blends in which at least one
blend component is a copolymer of propylene and at least one of
ethylene and an unsaturated comonomer.
BACKGROUND OF THE INVENTION
[0003] Polypropylene in its many and varied forms is a long
established staple of the polymer industry. Depending upon its
form, it exhibits a number of desirable properties including
toughness (as measured by any of a number of impact tests, e.g.,
notched Izod, dart drop, etc.), stiffness (as measured by any of a
number of modulus tests e.g., Young's), clarity, chemical
resistance and heat resistance. Often a particular combination of
properties is desired that requires a balancing of various
properties against one another (e.g., stiffness against
toughness).
[0004] Crystalline polypropylene, typically a homopolymer, is used
extensively in various moldings because it exhibits desirable
mechanical (e.g., rigidity) and chemical resistance properties. For
applications that require impact resistance (e.g., automobile
parts, appliance facia, packaging, etc.), a copolymer of propylene
and ethylene and/or one or more .alpha.-olefins is used, or a blend
of crystalline polypropylene with one or more polymers that exhibit
good impact resistance, e.g., ethylene-propylene (EP) and/or
ethylene-propylene-diene (EPDM) rubber. For applications that
require toughness and/or heat resistance (e.g., films), preferably
the polypropylene has a relatively low melt flow rate (MFR) or
expressed alternatively, a relatively high weight average molecular
weight (M.sub.w). For applications that require good processing
characteristics (e.g., fibers), preferably the polypropylene has a
relatively narrow polydisperity or molecular weight distribution
(MWD), e.g., less than 3.5.
[0005] Crystalline polypropylene has an isotactic structure, and it
is readily produced using a Ziegler-Natta (Z-N) or a metallocene
catalyst. While metallocene catalysts are effective for producing
propylene homo- and copolymers with a high isotactic index and a
relatively narrow MWD, to produce high M.sub.w, e.g., over 300,000,
propylene homo- or copolymers economically with a metallocene
catalyst is relatively difficult, especially in a solution process.
Moreover, the industry maintains a continuing interest in new
polypropylene polymers, particularly those for use in film
applications.
SUMMARY OF THE INVENTION
[0006] In a first embodiment, the invention is a film with
excellent machine direction (MD) tear properties. This film has at
least one layer having an MD tear of at least 75 grams/mil, and
this layer is made from a polymer comprising: [0007] (A) at least
50 weight percent (wt %) propylene; and [0008] (B) at least 5 wt %
ethylene and/or one or more unsaturated comonomers. Representative
of component (B) unsatuarated comonomers are the C.sub.4-20
.alpha.-olefins, C.sub.4-20 dienes, styrenic compounds, and the
like. Preferably, the film has at least one of a (i) haze value of
less than about 10, (ii) 45 degree gloss of greater than about 65,
and (iii) dart value of greater than about 100 g/mil, more
preferably greater than about 150 g/mil, further more prefereably
greater than 175 g/mil, and in some instances greater than 200
g/mil, most preferably greater than 250 g/mil, further most
preferably greater than 300 g/mil.
[0009] In a second embodiment, the invention is a film containing
at least one layer of a polymer comprising an isotactic propylene
homopolymer characterized as having .sup.13C NMR peaks
corresponding to a regio-error at about 14.6 and about 15.7 ppm,
the peaks of about equal intensity. Preferably, the propylene
homopolymer is characterized as having substantially isotactic
propylene sequences, i.e., the sequences have an isotactic triad
(mm) measured by .sup.13C NMR of greater than about 0.85. These
propylene homopolymers typically have at least 50 percent more of
this regio-error than a comparable polypropylene homopolymer
prepared with a Ziegler-Natta catalyst. A "comparable"
polypropylene as here used means an isotactic propylene homopolymer
having the same weight average molecular weight, i.e., within plus
or minus 10 wt %.
[0010] In a third embodiment, the invention is a film containing at
least one layer of a copolymer comprising propylene, ethylene and,
optionally, one or more unsaturated comonomers, e.g., C.sub.4-20
.alpha.-olefins, C.sub.4-20 dienes, vinyl aromatic compounds (e.g.,
styrene), etc. These copolymers are characterized as comprising at
least about 60 weight percent (wt %) of units derived from
propylene, about 0.1-35 wt % of units derived from ethylene, and 0
to about 35 wt % of units derived from one or more unsaturated
comonomers, with the proviso that the combined weight percent of
units derived from ethylene and the unsaturated comonomer does not
exceed about 40. These copolymers are also characterized as having
at least one of the following properties: (i) .sup.13C NMR peaks
corresponding to a regio-error at about 14.6 and about 15.7 ppm,
the peaks of about equal intensity, (ii) a B-value greater than
about 1.4 when the comonomer content, i.e., the units derived from
ethylene and/or the unsaturated comonomer(s), of the copolymer is
at least about 3 wt %, (iii) a skewness index, S.sub.ix, greater
than about -1.20, (iv) a DSC curve with a T.sub.me that remains
essentially the same and a T.sub.max that decreases as the amount
of comonomer, i.e., the units derived from ethylene and/or the
unsaturated comonomer(s), in the copolymer is increased, and (v) an
X-ray diffraction pattern that reports more gamma-form crystals
than a comparable copolymer prepared with a Ziegler-Natta (Z-N)
catalyst. Typically the copolymers of this embodiment are
characterized by at least two of these properties. Certain of the
copolymers of this embodiment are characterized by at least three
of these properties, while other copolymers of this embodiment are
characterized by at least four or even all five of these
properties.
[0011] With respect to the X-ray property of subparagraph (v)
above, a "comparable" copolymer is one having the same monomer
composition within 10 wt %, and the same M.sub.w within 10 wt %.
For example, if the propylene/ethylene/1-hexene copolymer is 9 wt %
ethylene and 1 wt % 1-hexene and has a Mw of 250,000, then a
comparable polymer would have from 8.1-9.9 wt % ethylene, 0.9-1.1
wt % 1-hexene, and a Mw between 225,000 and 275,000, prepared with
a Ziegler-Natta catalyst.
[0012] In a fourth embodiment, the invention is a film containing
at least one layer of a copolymer comprising propylene and one or
more unsaturated comonomers. These copolymers are characterized in
having at least about 60 wt % of the units derived from propylene,
and between about 0.1 and 40 wt % the units derived from the
unsaturated comonomer. These copolymers are also characterized as
having at least one of the following properties: (i) .sup.13C NMR
peaks corresponding to a regio-error at about 14.6 and about 15.7
ppm, the peaks of about equal intensity, (ii) a B-value greater
than about 1.4 when the comonomer content, i.e., the units derived
from the unsaturated comonomer(s), of the copolymer is at least
about 3 wt %, (iii) a skewness index, S.sub.ix, greater than about
-1.20, (iv) a DSC curve with a T.sub.me that remains essentially
the same and a T.sub.max that decreases as the amount of comonomer,
i.e., the units derived from the unsaturated comonomer(s), in the
copolymer is increased, and (v) an X-ray diffraction pattern that
reports more gamma-form crystals than a comparable copolymer
prepared with a Ziegler-Natta (Z-N) catalyst. Typically the
copolymers of this embodiment are characterized by at least two of
these properties. Certain of the copolymers of this embodiment are
characterized by at least three of these properties, while other
copolymers of this embodiment are characterized by at least four or
even all five of these properties.
[0013] In a fifth embodiment, the invention is a film containing at
least one layer of a blend of two or more polymers in which at
least one component of the blend, i.e., a first component,
comprises at least one of (i) one or more of the propylene/ethylene
and propylene/unsaturated comomoner copolymers described in the
third and fourth embodiments (occasionally referred to,
individually and collectively, as "P/E* copolymer" or similar
term), and (ii) one or more of the propylene homopolymer of the
second embodiment (occasionally referred to as "P* homopolymer" or
similar term). The amount of each polymer component in the blend
can vary widely, although preferably the first component comprises
at least about 50 weight percent of the blend. The blend may be
either homo- or heterophasic. If the latter, the P* homopolymer
and/or the P/E* copolymer can be either the continuous or
discontinuous (i.e., dispersed) phase.
[0014] P/E* copolymers are a unique subset of P/E copolymers. For
purposes of this disclosure, P/E copolymers comprise 50 weight
percent or more propylene while EP (ethylene-propylene) copolymers
comprise 51 weight percent or more ethylene. As here used,
"comprise . . . propylene", "comprise . . . ethylene" and similar
terms mean that the polymer comprises units derived from propylene,
ethylene or the like as opposed to the compounds themselves.
[0015] The other polymer component(s) in the blend of this fifth
embodiment can be one or more thermoplastic polymers other than the
P* and/or P/E* polymer that comprises the first component of the
blend. Typically and preferably, this other polymer(s) is (are) a
polyolefin such as one or more of a polyethylene,
ethylene/.alpha.-olefin (e.g., LLDPE, HDPE, LDPE, etc.),
butylene/.alpha.-olefin, ethylene/styrene and the like. The blend
may contain any weight percent, based on the total weight of the
blend, of these other components.
[0016] Other embodiments of the invention include articles made
from the inventive films and the processes of making these
articles. Illustrative articles include food and non-food packaging
films, bottles, tapes, ribbons, extrusion coatings and the like.
Many of these articles comprise multiple layers of film. The
processes used to make these articles include blown film, cast
film, calendering, extrusion coating, biaxial orienting and
compression molding.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 illustrates the unusual comonomer distribution of a
propylene/ethylene (P/E*) copolymer made with a metal-centered,
heteroaryl ligand catalyst.
[0018] FIGS. 2A and 2B show a comparison of the DSC heating traces
of the propylene/ethylene (P/E) copolymer of Comparative Example 1
and the P/E* copolymer of Example 2, respectively.
[0019] FIG. 3 shows a comparison of the Tg data of a P/E* copolymer
and a conventional Ziegler-Natta (Z-N) catalyzed P/E copolymer at
equivalent crystallinity.
[0020] FIG. 4 shows a comparison of the Tg data of a P/E* copolymer
and a conventional constrained geometry catalyst (CGC) P/E
copolymer at the same ethylene content.
[0021] FIG. 5 shows a comparison of a TREF curve for a conventional
metallocene-catalyzed P/E copolymer and a P/E* copolymer.
[0022] FIG. 6 shows the .sup.13C NMR spectrum of the propylene (P*)
homopolymer product of Example 7, prepared using Catalyst G. This
spectrum shows the high degree of isotacticity of the product.
[0023] FIG. 7 shows the .sup.13C NMR spectrum of the P* homopolymer
product of Example 8 prepared using Catalyst H. This spectrum is
shown at an expanded Y-axis scale relative to FIG. 6 in order to
more clearly show the regio-error peaks.
[0024] FIG. 8 shows the .sup.13C NMR Spectrum of the P/E* copolymer
product of Example 2 prepared using Catalyst G.
[0025] FIG. 9 shows the .sup.13C NMR Spectrum of the P/E copolymer
product of Comparative Example 1 prepared using metallocene
Catalyst E demonstrating the absence of regio-error peaks in the
region around 15 ppm.
[0026] FIG. 10 is a bar graph comparing the elasticity of
unstretched P/E* copolymers against various conventional
unstretched thermoplastic elastomers.
[0027] FIG. 11 is a bar graph comparing the elasticity of
pre-stretched P/E* copolymers against various conventional
pre-stretched thermoplastic elastomers.
[0028] FIGS. 12A-12J show the chemical structures of various
catalysts.
[0029] FIGS. 13A and 13B show the DSC heating and cooling traces of
the P* homopolymer of Example 8, prepared using Catalyst H.
[0030] FIG. 14 shows a comparison of the skewness index for a P/E*
copolymer and several P/E copolymers.
[0031] FIG. 15 compares the melting endotherms of Samples 8 and 22a
of Example 11.
[0032] FIG. 16 demonstrates the shift in peak melting temperature
towards lower temperature for the P/E* copolymer of Example 11.
[0033] FIG. 17 is a plot of the temperature at which approximately
1 percent crystallinity remains in DSC samples of Example 11.
[0034] FIG. 18 shows the variance relative to the first moment of
the melting endotherm as a function of the heat of melting of
various samples of Example 11.
[0035] FIG. 19 shows the maximum heat flow normalized by the heat
of melting as a function of the heat of melting for various samples
of Example 11.
[0036] FIG. 20 illustrates that the rate at which the last portion
of crystallinity disappears in P/E* polymers is significantly lower
than for metallocene-catalyzed polymers.
[0037] FIG. 21 illustrates the cling percent for two A/B film
structures tested with the A layer of the first film in contact
with the B layer of the second film, in which the A layers in both
structures are made from a P/E* copolymer.
[0038] FIG. 22 illustrates the cling percent for two A/B film
structures tested with the A layer of the first film in contact
with the A layer of the second film. Both A layers are made from a
P/E* copolymer.
[0039] FIG. 23 shows the heat seal behavior for the P/E* polymers
compared to Ziegler-Natta catalyzed polymers ("ZN catalyzed
polymers").
[0040] FIG. 24 shows the hot tack behavior for the P/E* polymers
compared to Ziegler-Natta catalyzed polymers.
[0041] FIG. 25 shows the heat seal behavior for blends of
propylene-ethylene copolymers with metallocene catalyzed
ethylene/alpha-olefin copolymer.
[0042] FIG. 26 shows the heat seal behavior for blends of
mini-random propylene-ethylene copolymers with P/E* copolymers.
[0043] FIG. 27 shows the heat seal behavior for blends of P/E*
copolymers with a mini-random propylene-ethylene copolymer.
[0044] FIG. 28 shows the 2% secant modulus (as determined by ASTM
D882) for blends of P/E* copolymers with a mini-random
propylene-ethylene copolymers.
[0045] FIG. 29 shows the heat seal behavior for a blend of a P/E*
copolymer with a random propylene-ethylene copolymer.
[0046] FIG. 30 compares the heat seal behavior of a blend of a P/E*
copolymer with a random propylene-ethylene copolymer with the heat
seal behavior of a blend of a P/E* copolymer with mini-random
propylene-ethylene copolymer.
[0047] FIG. 31 shows the heat seal behavior for a blend of P/E*
copolymer with and without an added nucleating agent.
[0048] FIG. 32 shows the hot tack behavior of blends of P/E*
copolymers with a random propylene-ethylene copolymer.
[0049] FIG. 33 shows the hot tack behavior of blends of P/E*
copolymers with a mini-random propylene-ethylene copolymer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Molecular Weight
[0050] The weight average molecular weight (Mw) of the polymers
used in this invention can vary widely, but typically it is between
about 30,000 and 1,000,000 (with the understanding that the only
limit on the minimum or the maximum M.sub.w is that set by
practical considerations). Preferably the minimum Mw is about
50,000, more preferably about 75,000 and even more preferably about
100,000. "High molecular weight", "high weight average molecular
weight", "high Mw" and similar terms mean a weight average
molecular weight of at least about 250,000, preferably of at least
about 300,000 and more preferably 350,000, and more preferably at
least about 400,000.
Polydispersity
[0051] The polydispersity of the polymers used in the films of this
invention is typically between about 2 and about 6. "Narrow
polydisperity", "narrow molecular weight distribution", "narrow
MWD" and similar terms mean a ratio (M.sub.w/M.sub.n) of weight
average molecular weight (M.sub.w) to number average molecular
weight (M.sub.n) of less than about 3.5, preferably less than about
3.0, more preferably less than about 2.8, more preferably less than
about 2.5, and most preferably less than about 2.3. Polymers for
use in extrusion coating applications typically have a narrow
polydispersity.
[0052] The polydispersity of the polymer blends used in the films
of his invention may have greater than that of the individual
polymer components of the blend depending, in part, on the
molecular weight of the individual blend components. In particular,
blends produced utilizing a multiple reactor processes, such as
those disclosed below, may have a broad range of polydispersities,
e.g., from as low as about 2 to as high as about 100 or more.
Preferably, the M.sub.w/M.sub.n of such blends is between about 2
and about 50, more preferably between about 2 and about 20, most
preferably between about 2 and about 10.
Gel Permeation Chromatography
[0053] Molecular weight distribution of the crystallizable
propylene polymers is determined using gel permeation
chromatography (GPC) on a Polymer Laboratories PL-GPC-220 high
temperature chromatographic unit equipped with four linear mixed
bed columns (Polymer Laboratories (20-micron particle size)). The
oven temperature is at 160.degree. C. with the autosampler hot zone
at 160.degree. C. and the warm zone at 145.degree. C. The solvent
is 1,2,4-trichlorobenzene containing 200 ppm
2,6-di-t-butyl-4-methylphenol. The flow rate is 1.0
milliliter/minute and the injection size is 100 microliters. About
0.2% by weight solutions of the samples are prepared for injection
by dissolving the sample in nitrogen purged 1,2,4-trichlorobenzene
containing 200 ppm 2,6-di-t-butyl-4-methylphenol for 2.5 hrs at
160.degree. C. with gentle mixing.
[0054] The molecular weight determination is deduced by using ten
narrow molecular weight distribution polystyrene standards (from
Polymer Laboratories, EasiCal PS1 ranging from 580-7,500,000
g/mole) in conjunction with their elution volumes. The equivalent
polypropylene molecular weights are determined by using appropriate
Mark-Houwink coefficients for polypropylene (as described by Th. G.
Scholte, N. L. J. Meijerink, H. M. Schoffeleers, and A. M. G.
Brands, J. Appl. Polym. Sci., 29, 3763-3782 (1984)) and polystyrene
(as described by E. P. Otocka, R. J. Roe, N. Y. Hellman, P. M.
Muglia, Macromolecules, 4, 507 (1971)) in the Mark-Houwink
equation: {N}=KM.sup.a where K.sub.pp=1.90E-04, a.sub.pp=0.725 and
K.sub.ps=1.26E-04, a.sub.ps=0.702. Differential Scanning
Calorimetry
[0055] Differential scanning calorimetry (DSC) is a common
technique that can be used to examine the melting and
crystallization of semi-crystalline polymers. General principles of
DSC measurements and applications of DSC to studying
semi-crystalline polymers are described in standard texts (e.g., E.
A. Turi, ed., Thermal Characterization of Polymeric Materials,
Academic Press, 1981). Certain of the copolymers used in the
practice of this invention are characterized by a DSC curve with a
T.sub.me that remains essentially the same and a T.sub.max that
decreases as the amount of unsaturated comonomer in the copolymer
is increased. T.sub.me means the temperature at which the melting
ends. T.sub.max means the peak melting temperature.
[0056] Differential Scanning Calorimetry (DSC) analysis is
determined using a model Q1000 DSC from TA Instruments, Inc.
Calibration of the DSC is done as follows. First, a baseline is
obtained by running the DSC from -90.degree. C. to 290.degree. C.
without any sample in the aluminum DSC pan. Then 7 milligrams of a
fresh indium sample is analyzed by heating the sample to
180.degree. C., cooling the sample to 140.degree. C. at a cooling
rate of 10.degree. C./min followed by keeping the sample
isothermally at 140.degree. C. for 1 minute, followed by heating
the sample from 140.degree. C. to 180.degree. C. at a heating rate
of 10.degree. C./min. The heat of fusion and the onset of melting
of the indium sample are determined and checked to be within
0.5.degree. C. from 156.6.degree. C. for the onset of melting and
within 0.5 J/g from 28.71 J/g for the heat of fusion. Then
deionized water is analyzed by cooling a small drop of fresh sample
in the DSC pan from 25.degree. C. to -30.degree. C. at a cooling
rate of 10.degree. C./min. The sample is kept isothermally at
-30.degree. C. for 2 minutes and heated to 30.degree. C. at a
heating rate of 10.degree. C./min. The onset of melting is
determined and checked to be within 0.5.degree. C. from 0.degree.
C.
[0057] The polypropylene samples are pressed into a thin film at a
temperature of 190.degree. C. About 5 to 8 mg of sample is weighed
out and placed in the DSC pan. The lid is crimped on the pan to
ensure a closed atmosphere. The sample pan is placed in the DSC
cell and the heated at a high rate of about 100.degree. C./min to a
temperature of about 30.degree. C. above the melt temperature. The
sample is kept at this temperature for about 3 minutes. Then the
sample is cooled at a rate of 10.degree. C./min to -40.degree. C.,
and kept isothermally at that temperature for 3 minutes.
Consequently the sample is heated at a rate of 10.degree. C./min
until complete melting. The resulting enthalpy curves are analyzed
for peak melt temperature, onset and peak crystallization
temperatures, heat of fusion and heat of crystallization, T.sub.me,
and any other DSC analyses of interest.
B-Value
[0058] "High B-value" and similar terms mean the ethylene units of
a copolymer of propylene and ethylene, or a copolymer of propylene,
ethylene and at least one unsaturated comonomer, is distributed
across the polymer chain in a nonrandom manner. B-values range from
0 to 2 with 1 designating a perfectly random distribution of
comonomer units. The higher the B-value, the more alternating the
comonomer distribution in the copolymer. The lower the B-value, the
more blocky or clustered the comonomer distribution in the
copolymer. The high B-values of the polymers of this invention are
typically at least about 1.3, preferably at least about 1.4, more
preferably at least about 1.5 and most preferably at least about
1.7. The B-value is calculated as follows.
[0059] B is defined for a propylene/ethylene copolymer as: B = f
.function. ( E .times. .times. P + P .times. .times. E ) 2 F E F P
##EQU1## where f(EP+PE)=the sum of the EP and PE diad fractions;
and Fe and Fp=the mole fraction of ethylene and propylene in the
copolymer, respectively. B-values can be calculated for other
copolymers in an analogous manner by assignment of the respective
copolymer diads. For example, calculation of the B-value for a
propylene/1-octene copolymer uses the following equation: B = f
.function. ( O .times. .times. P + P .times. .times. O ) 2 F O F P
##EQU2##
[0060] For propylene polymers made with a metallocene catalyst, the
B-values are typically between 1.1 and 1.3. For propylene polymers
made with a constrained geometry catalyst, the B-values are
typically between 0.9 and 1.0. In contrast, the B-values of the
propylene polymers of this invention, typically made with an
activated nonmetallocene, metal-centered, heteroaryl ligand
catalyst, are above about 1.4, typically between about 1.5 and
about 1.85. In turn, this means that for any P/E* copolymer, not
only is the propylene block length relatively short for a given
percentage of ethylene but very little, if any, long sequences of 3
or more sequential ethylene insertions are present in the
copolymer, unless the ethylene content of the polymer is very high.
FIG. 1 and the data of the following tables are illustrative. The
catalysts are activated nonmetallocene, metal-centered, heteroaryl
ligand catalysts, and these made P/E* polymers. The Catalyst E is a
metallocene catalyst, and it did not make the P/E* polymers.
Interestingly, the B-values of the P/E* polymers remained high even
for polymers with relatively large amounts, e.g., >30 mole %,
ethylene. TABLE-US-00001 TABLE A B-Values of Selected Propylene
Polymers Regio-errors 14-16 ppm MFR Density Ethylene (mole %) Tmax
Cryst. (%) Tg No Description (g/10 min) (kg/dm 3#) (mol %) (average
of two) B (.degree. C.) (from Hf) (.degree. C.) A-1 P/E* via
Catalyst I 25.8 0.8864 10.6 0.00 1.40 104.7 37.3 -20.9 A-2 HPP via
Catalyst G 1.9 0.8995 0.0 1.35 None 139.5 48.7 -6.9 A-3 P/E* via
Catalyst G 1.7 0.8740 11.8 0.24 1.67 63.3 24.4 -23.6 A-4 P/E* via
Catalyst G 1.5 0.8703 12.9 0.32 1.66 57.7 21.9 -24.5 A-5 HPP via
Catalyst H 2.5 0.9021 0.0 1.18 none 143.5 61.4 -6.0 A-6 P/E* via
Catalyst H 1.9 0.8928 4.3 0.57 1.77 120.6 48.3 -13.8 A-7 P/E* via
Catalyst H 2.2 0.8850 8.2 0.47 1.71 96.0 40.5 -19.3 A-8 P/E* via
Catalyst H 2.3 0.8741 11.8 0.34 1.79 67.9 27.4 -23.7 A-9 P/E* via
Catalyst H 2 0.8648 15.8 0.24 1.67 53.7 10.5 -27.6 A-10 P/E* via
Catalyst H 2.0 0.8581 18.6 0.18 1.70 none 2.6 -29.9
[0061] Catalyst I is
dimethyleamidoborane-bis-.eta..sup.5-(2-methyl-4-napthylinden-1-yl)zircon-
ium .eta..sup.4-1,4-dipheny-1,3-butadiene. HPP means polypropylene
homopolymer. TABLE-US-00002 TABLE B B-Values of Selected
Propylene/Ethylene Copolymers Regio-errors 14-16 ppm (mole Ethylene
%) (average of Tmax Cryst. (%) Tg Number Description (mol %) two) B
(.degree. C.) (from Hf) (.degree. C.) B-1 P/E* via Catalyst H 1.6
0.37 1.78 138.2 53.9 -8.1 B-2 P/E* via Catalyst H 7.7 0.38 1.66
105.6 38.9 -18.5 B-3 P/E* via Catalyst H 7.8 0.41 1.61 107.7 39.6
-18.2 B-4 P/E* via Catalyst H 12.3 0.31 1.58 74.7 30.7 -22.5 B-5
P/E* via Catalyst H 14.8 0.21 1.67 90.6 31.2 -22.9 B-6 P/E* via
Catalyst H 12.4 0.31 1.61 67.4 20.8 -26.8 B-7 P/E* via Catalyst H
14.7 0.30 1.60 78.1 19.9 -25.9 B-8 P/E* via Catalyst H 33.7 0.00
1.67 none 0.0 -39.2 B-9 P/E* via Catalyst H 31.3 0.00 1.67 none 0.0
-39.2 B-10 P/E* via Catalyst J 12.0 0.25 1.61 72.4 33.2 -22.8 B-11
P/E* via Catalyst J 8.9 0.37 1.63 91.4 40.1 -19.8 B-12 P/E* via
Catalyst J 8.5 0.44 1.68 101.7 38.7 -20.0 B-13 P/E* via Catalyst J
7.6 0.47 1.68 107.6 43.2 -18.8 B-14 P/E* via Catalyst J 7.6 0.35
1.64 106.2 42.4 -18.5 B-15 P/E* via Catalyst J 8.6 0.33 1.64 104.4
41.0 -19.5 B-16 P/E* via Catalyst J 9.6 0.35 1.65 85.5 38.1 -20.6
B-17 P/E* via Catalyst J 8.6 0.37 1.63 104.1 41.8 -19.6 B-18 P/E*
via Catalyst J 8.6 0.34 1.62 90.8 40.8 -19.6 B-19 P/E* via Catalyst
J 8.6 0.40 1.58 93.3 41.9 -19.2
[0062] The processes described below can be used to produce
propylene interpolymers of ethylene and optionally C.sub.4-C.sub.20
alpha-olefins having a relatively broad melting point in a DSC
heating curve. While not wishing to be held to any particular
theory of operation, it is believed that the high B values for the
novel propylene/ethylene interpolymers and the process for their
manufacture lead to an ethylene distribution within the polymer
chains that leads to a broad melting behavior. In FIGS. 2A and 2B,
for example, a relatively narrow melting peak is observed for a
propylene/ethylene copolymer prepared using a metallocene as a
comparative example (Comparative Example 1), while the melting peak
for a similar copolymer of propylene and ethylene prepared
according to the teachings herein exhibits a broad melting point.
Such broad melting behavior is useful in applications requiring,
for example, a relatively low heat seal initiation temperature, or
a broad hot tack and/or heat seal window.
Thermal Properties
[0063] FIGS. 3 and 4 further illustrate the thermal properties of
the P/E* polymers used in the practice of this invention. FIG. 3
illustrates that the P/E* polymers have a higher glass transition
temperature (Tg) than do comparable metallocene-catalysed propylene
polymers at a equivalent crystallinity. This means that the P/E*
copolymers are likely to exhibit better creep resistance than
conventional metallocene-catalyzed propylene copolymers. Moreover,
the T.sub.max data of Table A shows that the P/E* copolymers have a
lower melting point at the same crystallinity as a
metallocene-catalyzed propylene copolymer. This, in turn, means
that the P/E* polymers are likely to process better (e.g., require
less heating) than conventional metallocene-catalyzed propylene
polymers.
[0064] FIG. 4 illustrates that the P/E* polymers also have a lower
Tg at an equivalent ethylene content than a propylene polymer made
with a constrained geometry catalyst (CGC) and this, in turn, means
that the P/E* polymers are likely to exhibit better low temperature
toughness than the CGC propylene polymers making the P/E* polymers
attractive candidates for food packaging applications.
Temperature-Rising Elution Fractionation
[0065] The determination of crystallizable sequence length
distribution can be accomplished on a preparative scale by
temperature-rising elution fractionation (TREF). The relative mass
of individual fractions can be used as a basis for estimating a
more continuous distribution. L. Wild, et al., Journal of Polymer
Science: Polymer. Physics Ed., 20, 441 (1982), scaled down the
sample size and added a mass detector to produce a continuous
representation of the distribution as a function of elution
temperature. This scaled down version, analytical
temperature-rising elution fractionation (ATREF), is not concerned
with the actual isolation of fractions, but with more accurately
determining the weight distribution of fractions.
[0066] While TREF was originally applied to copolymers of ethylene
and higher .alpha.-olefins, it can also be used for the analysis of
copolymers of propylene with ethylene (or higher .alpha.-olefins).
The analysis of copolymers of propylene requires higher
temperatures for the dissolution and crystallization of pure,
isotactic polypropylene, but most of the copolymerization products
of interest elute at similar temperatures as observed for
copolymers of ethylene. The following table is a summary of
conditions used for the analysis of copolymers of propylene. Except
as noted the conditions for TREF are consistent with those of Wild,
et al., ibid, and Hazlitt, Journal of Applied Polymer Science:
Appl. Polym. Symp., 45, 25(1990). TABLE-US-00003 TABLE C Parameters
Used for TREF Parameter Explanation Column type and size Stainless
steel shot with1.5 cc interstitial volume Mass detector Single beam
infrared detector at 2920 cm.sup.-1 Injection temperature
150.degree. C. Temperature control GC oven device Solvent
1,2,4-trichlorobenzene Concentration 0.1 to 0.3% (weight/weight)
Cooling Rate 1 140.degree. C. to 120.degree. C. @ -6.0.degree.
C./min. Cooling Rate 2 120.degree. C. to 44.5.degree. C. @
-0.1.degree. C./min. Cooling Rate 3 44.5.degree. C. to 20.degree.
C. @ -0.3.degree. C./min. Heating Rate 20.degree. C. to 140.degree.
C. @ 1.8.degree. C./min. Data acquisition rate 12/min.
[0067] The data obtained from TREF are expressed as a normalized
plot of weight fraction as a function of elution temperature. The
separation mechanism is analogous to that of copolymers of
ethylene, whereby the molar content of the crystallizable component
(ethylene) is the primary factor that determines the elution
temperature. In the case of copolymers of propylene, it is the
molar content of isotactic propylene units that primarily
determines the elution temperature. FIG. 5 is a representation of
the typical type of distribution one would expect for a
propylene/ethylene copolymer made with a metallocene polymer and an
example of a P/E* copolymer.
[0068] The shape of the metallocene curve in FIG. 5 is typical for
a homogeneous copolymer. The shape arises from the inherent, random
incorporation of comonomer. A prominent characteristic of the shape
of the curve is the tailing at lower elution temperature compared
to the sharpness or steepness of the curve at the higher elution
temperatures. A statistic that reflects this type of asymmetry is
skewness. Equation 1 mathematically represents the skewness index,
S.sub.ix, as a measure of this asymmetry. S ix = w i * ( T i - T
Max ) 3 3 w i * ( T i - T Max ) 2 . Equation .times. .times. 1
##EQU3##
[0069] The value, T.sub.Max, is defined as the temperature of the
largest weight fraction eluting between 50 and 90.degree. C. in the
TREF curve. T.sub.i and w.sub.i are the elution temperature and
weight fraction respectively of an arbitrary, i.sup.th fraction in
the TREF distribution. The distributions have been normalized (the
sum of the w.sub.i equals 100%) with respect to the total area of
the curve eluting above 30.degree. C. Thus, the index reflects only
the shape of the crystallized polymer and any uncrystallized
polymer (polymer still in solution at or below 30.degree. C.) has
been omitted from the calculation shown in Equation 1.
Polymer Definitions and Descriptions
[0070] "Polymer" means a macromolecular compound prepared by
polymerizing monomers of the same or different type. "Polymer"
includes homopolymers, copolymers, terpolymers, interpolymers, and
so on. The term "interpolymer" means a polymer prepared by the
polymerization of at least two types of monomers or comonomers. It
includes, but is not limited to, copolymers (which usually refers
to polymers prepared from two different types of monomers or
comonomers, although it is often used interchangeably with
"interpolymer" to refer to polymers made from three or more
different types of monomers or comonomers), terpolymers (which
usually refers to polymers prepared from three different types of
monomers or comonomers), tetrapolymers (which usually refers to
polymers prepared from four different types of monomers or
comonomers), and the like. The terms "monomer" or "comonomer" are
used interchangeably, and they refer to any compound with a
polymerizable moiety which is added to a reactor in order to
produce a polymer. In those instances in which a polymer is
described as comprising one or more monomers, e.g., a polymer
comprising propylene and ethylene, the polymer, of course,
comprises units derived from the monomers, e.g.,
--CH.sub.2--CH.sub.2--, and not the monomer itself, e.g.,
CH.sub.2.dbd.CH.sub.2.
[0071] "Metallocene-catalyzed polymer" or similar term means any
polymer that is made in the presence of a metallocene catalyst.
"Constrained geometry catalyst catalyzed polymer", "CGC-catalyzed
polymer" or similar term means any polymer that is made in the
presence of a constrained geometry catalyst.
"Ziegler-Natta-catalyzed polymer", Z-N-catalyzed polymer" or
similar term means any polymer that is made in the presence of a
Ziegler-Natta catalyst. "Metallocene" means a metal-containing
compound having at least one substituted or unsubstituted
cyclopentadienyl group bound to the metal. "Constrained geometry
catalyst" or "CGC" as here used has the same meaning as this term
is defined and described in U.S. Pat. Nos. 5,272,236 and
5,278,272.
[0072] "Random copolymer" means a copolymer in which the monomer is
randomly distributed across the polymer chain.
[0073] "Propylene homopolymer" and similar terms mean a polymer
consisting solely or essentially all of units derived from
propylene. "Polypropylene copolymer" and similar terms mean a
polymer comprising units derived from propylene and ethylene and/or
one or more unsaturated comonomers. The term "copolymer" includes
terpolymers, tetrapolymers, etc.
[0074] The unsaturated comonomers used in the practice of this
invention include C.sub.4-20 .alpha.-olefins, especially C.sub.4-12
.alpha.-olefins such as 1-butene, 1-pentene, 1-hexene,
4-methyl-1-pentene, 1-heptene, 1-octene, 1-decene, 1-dodecene and
the like; C.sub.4-20 diolefins, preferably 1,3-butadiene,
1,3-pentadiene, norbornadiene, 5-ethylidene-2-norbornene (ENB) and
dicyclopentadiene; C.sub.8-40 vinyl aromatic compounds including
sytrene, o-, m-, and p-methylstyrene, divinylbenzene,
vinylbiphenyl, vinylnapthalene; and halogen-substituted C.sub.8-40
vinyl aromatic compounds such as chlorostyrene and fluorostyrene.
For purposes of this invention, ethylene and propylene not included
in the definition of unsaturated comonomers.
[0075] The propylene copolymers used in the practice of this
invention typically comprise units derived from propylene in an
amount of at least about 60, preferably at least about 80 and more
preferably at least about 85, wt % of the copolymer. The typical
amount of units derived from ethylene in propylene/ethylene
copolymers is at least about 0.1, preferably at least about 1 and
more preferably at least about 5 wt %, and the maximum amount of
units derived from ethylene present in these copolymers is
typically not in excess of about 35, preferably not in excess of
about 30 and more preferably not in excess of about 20, wt % of the
copolymer. The amount of units derived from the unsaturated
comonomer(s), if present, is typically at least about 0.01,
preferably at least about 1 and more preferably at least about 5,
wt %, and the typical maximum amount of units derived from the
unsaturated comonomer(s) typically does not exceed about 35,
preferably it does not exceed about 30 and more preferably it does
not exceed about 20, wt % of the copolymer. The combined total of
units derived from ethylene and any unsaturated comonomer typically
does not exceed about 40, preferably it does not exceed about 30
and more preferably it does not exceed about 20, wt % of the
copolymer.
[0076] The copolymers used in the practice of this invention
comprising propylene and one or more unsaturated comonomers (other
than ethylene) also typically comprise units derived from propylene
in an amount of at least about 60, preferably at least about 70 and
more preferably at least about 80, wt % of the copolymer. The one
or more unsaturated comonomers of the copolymer comprise at least
about 0.1, preferably at least about 1 and more preferably at least
about 3, weight percent, and the typical maximum amount of
unsaturated comonomer does not exceed about 40, and preferably it
does not exceed about 30, wt % of the copolymer.
.sup.13C NMR
[0077] The P/E* polymers used in the practice of this invention are
further characterized as having substantially isotactic propylene
sequences. "Substantially isotactic propylene sequences" and
similar terms mean that the sequences have an isotactic triad (mm)
measured by .sup.13C NMR of greater than about 0.85, preferably
greater than about 0.90, more preferably greater than about 0.92
and most preferably greater than about 0.93. Isotactic triads are
well known in the art and are described in, for example, U.S. Pat.
No. 5,504,172 and WO 00/01745 which refer to the isotactic sequence
in terms of a triad unit in the copolymer molecular chain
determined by .sup.13C NMR spectra. The NMR spectra are determined
as follows.
[0078] .sup.13C NMR spectroscopy is one of a number of techniques
known in the art of measuring comonomer incorporation into a
polymer. An example of this technique is described for the
determination of comonomer content for ethylene/.alpha.-olefin
copolymers in Randall (Journal of Macromolecular Science, Reviews
in Macromolecular Chemistry and Physics, C29 (2 & 3), 201-317
(1989)). The basic procedure for determining the comonomer content
of an olefin interpolymer involves obtaining the .sup.13C NMR
spectrum under conditions where the intensity of the peaks
corresponding to the different carbons in the sample is directly
proportional to the total number of contributing nuclei in the
sample. Methods for ensuring this proportionality are known in the
art and involve allowance for sufficient time for relaxation after
a pulse, the use of gated-decoupling techniques, relaxation agents,
and the like. The relative intensity of a peak or group of peaks is
obtained in practice from its computer-generated integral. After
obtaining the spectrum and integrating the peaks, those peaks
associated with the comonomer are assigned. This assignment can be
made by reference to known spectra or literature, or by synthesis
and analysis of model compounds, or by the use of isotopically
labeled comonomer. The mole % comonomer can be determined by the
ratio of the integrals corresponding to the number of moles of
comonomer to the integrals corresponding to the number of moles of
all of the monomers in the interpolymer, as described in Randall,
for example.
[0079] The data is collected using a Varian UNITY Plus 400 MHz NMR
spectrometer, corresponding to a .sup.13C resonance frequency of
100.4 MHz. Acquisition parameters are selected to ensure
quantitative .sup.13C data acquisition in the presence of the
relaxation agent. The data is acquired using gated .sup.1H
decoupling, 4000 transients per data file, a 7 sec pulse repetition
delay, spectral width of 24,200 Hz and a file size of 32 K data
points, with the probe head heated to 130.degree. C. The sample is
prepared by adding approximately 3 mL of a 50/50 mixture of
tetrachloroethane-d2/orthodichlorobenzene that is 0.025M in
chromium acetylacetonate (relaxation agent) to 0.4 g sample in a 10
mm NMR tube. The headspace of the tube is purged of oxygen by
displacement with pure nitrogen. The sample is dissolved and
homogenized by heating the tube and its contents to 150.degree. C.
with periodic refluxing initiated by heat gun.
[0080] Following data collection, the chemical shifts are
internally referenced to the mmmm pentad at 21.90 ppm.
[0081] For propylene/ethylene copolymers, the following procedure
is used to calculate the percent ethylene in the polymer. Integral
regions are determined as follows: TABLE-US-00004 TABLE D Integral
Regions for Determining % Ethylene Region designation Ppm A 44-49 B
36-39 C 32.8-34 P 31.0-30.8 Q Peak at 30.4 R Peak at 30 F 28.0-29.7
G 26-28.3 H 24-26 I 19-23
[0082] Region D is calculated as D=P-(G-Q)/2. Region E=R+Q+(G-Q)/2.
TABLE-US-00005 TABLE E Calculation of Region D PPP = (F + A - 0.5
D)/2 PPE = D EPE = C EEE = (E - 0.5 G)/2 PEE = G PEP = H Moles P =
sum P centered triads Moles E = sum E centered triads Moles P = (B
+ 2A)/2 Moles E = (E + G + 0.5B + H)/2
[0083] C2 values are calculated as the average of the two methods
above (triad summation and algebraic) although the two do not
usually vary.
[0084] The mole fraction of propylene insertions resulting in
regio-errors is calculated as one half of the sum of the two of
methyls showing up at 14.6 and 15.7 ppm divided by the total
methyls at 14-22 ppm attributable to propylene. The mole percent of
the regio-error peaks is the mole fraction times 100.
[0085] Isotacticity at the triad level (mm) is determined from the
integrals of the mm triad (22.70-21.28 ppm), the mr triad
(21.28-20.67 ppm) and the rr triad (20.67-19.74). The mm
isotacticity is determined by dividing the intensity of the mm
triad by the sum of the mm, mr, and rr triads. For ethylene
copolymers the mr region is corrected by subtracting 37.5-39 ppm
integral. For copolymers with other monomers that produce peaks in
the regions of the mm, mr, and rr triads, the integrals for these
regions are similarly corrected by subtracting the intensity of the
interfering peak using standard NMR techniques, once the peaks have
been identified. This can be accomplished, for example, by analysis
of a series of copolymers of various levels of monomer
incorporation, by literature assignments, by isotopic labeling, or
other means which are known in the art.
[0086] The .sup.13C NMR peaks corresponding to a regio-error at
about 14.6 and about 15.7 ppm are believed to be the result of
stereoselective 2,1-insertion errors of propylene units into the
growing polymer chain. In a typical P/E* polymer, these peaks are
of about equal intensity, and they represent about 0.02 to about 7
mole percent of the propylene insertions into the homopolymer or
copolymer chain. For some embodiments, they represent about 0.005
to about 20 mole % or more of the propylene insertions. In general,
higher levels of regio-errors lead to a lowering of the melting
point and the modulus of the polymer, while lower levels lead to a
higher melting point and a higher modulus of the polymer.
[0087] The nature and level of comonomers other than propylene also
control the melting point and modulus of the copolymer. In any
particular application, it may be desirable to have either a high
or low melting point or a high or low modulus modulus. The level of
regio-errors can be controlled by several means, including the
polymerization temperature, the concentration of propylene and
other monomers in the process, the type of (co)monomers, and other
factors. Various individual catalyst structures may inherently
produce more or less regio-errors than other catalysts. For
example, in Table A above, the propylene homopolymer prepared with
Catalyst G has a higher level of regio-errors and a lower melting
point than the propylene homopolymer prepared with Catalyst H,
which has a higher melting point. If a higher melting point (or
higher modulus) polymer is desired, then it is preferable to have
fewer regio-errors than about 3 mole % of the propylene insertions,
more preferably less than about 1.5 mole % of the propylene
insertions, still more preferably less than about 1.0 mole % of the
propylene insertions, and most preferably less than about 0.5 mole
% of the propylene insertions. If a lower melting point (or
modulus) polymer is desired, then it is preferable to have more
regio-errors than about 3 mole % of the propylene insertions, more
preferably more than about 5 mole % of the propylene insertions,
still more preferably more than about 6 mole % of the propylene
insertions, and most preferably more than about 10 mole % of the
propylene insertions.
[0088] Those skilled artisan will appreciate that the mole % of
regio-errors for a P/E* polymer which is a component of a blend
refers to the mole % of regio-errors of the particular P/E* polymer
component of the blend, and not as a mole % of the overall
blend.
[0089] The comparison of several .sup.13C NMR spectra further
illustrates the unique regio-errors of the P/E* polymers. FIGS. 6
and 7 are the spectra of the propylene homopolymer products of
Examples 7 and 8, respectively, each made with an activated
nonmetallocene, metal-centered, heteroaryl ligand catalyst. The
spectrum of each polymer reports a high degree of isotacticity and
the unique regio-errors of these inventive polymers. FIG. 8 is the
.sup.13C NMR spectrum of the propylene-ethylene copolymer of
Example 2, made with the same catalyst used to make the propylene
homopolymer of Example 7, and it too reports a high degree of
isotacticity and the same regio-errors of the propylene
homopolymers of FIG. 9. The presence of the ethylene comonomer does
not preclude the occurrence of these unique regio-errors. The
.sup.13C NMR spectrum of FIG. 9 is that of the propylene-ethylene
copolymer product of Comparative Example 1 which was prepared using
a metallocene catalyst. This spectrum does not report the
regio-error (around 15 ppm) characteristic of the P/E*
polymers.
Melt Flow Rate (MFR)
[0090] The propylene homo- and copolymers used in this invention
typically have an MFR of at least about 0.01, preferably at least
about 0.05, more preferably at least about 0.1 and most preferably
at least about 0.2. The maximum MFR typically does not exceed about
1,000, preferably it does not exceed about 500, more preferably it
does not exceed about 100, more preferably it does not exceed about
80 and most preferably it does not exceed about 50. The MFR for
propylene homopolymers and copolymers of propylene and ethylene
and/or one or more C.sub.4-C.sub.20 .alpha.-olefins is measured
according to ASTM D-1238, condition L (2.16 kg, 230 degrees
C.).
Propylene Copolymers
[0091] The propylene copolymers used in this invention of
particular interest include propylene/ethylene, propylene/1-butene,
propylene/1-hexene, propylene/4-methyl-1-pentene,
propylene/1-octene, propylene/ethylene/1-butene,
propylene/ethylene/ENB, propylene/ethylene/1-hexene,
propylene/ethylene/1-octene, propylene/styrene, and
propylene/ethylene/styrene.
Catalyst Definitions and Descriptions
[0092] The P* and P/E* polymers used in the practice of this
invention are made using a metal-centered, heteroaryl ligand
catalyst in combination with one or more activators, e.g., an
alumoxane. In certain embodiments, the metal is one or more of
hafnium and zirconium.
[0093] More specifically, in certain embodiments of the catalyst,
the use of a hafnium metal has been found to be preferred as
compared to a zirconium metal for heteroaryl ligand catalysts. A
broad range of ancillary ligand substituents may accommodate the
enhanced catalytic performance. The catalysts in certain
embodiments are compositions comprising the ligand and metal
precursor, and, optionally, may additionally include an activator,
combination of activators or activator package.
[0094] The catalysts used to make the P* and P/E* polymers
additionally include catalysts comprising ancillary ligand-hafnium
complexes, ancillary ligand-zirconium complexes and optionally
activators, which catalyze polymerization and copolymerization
reactions, particularly with monomers that are olefins, diolefins
or other unsaturated compounds. Zirconium complexes, hafnium
complexes, compositions or compounds using the disclosed ligands
are within the scope of the catalysts useful in the practice of
this invention. The metal-ligand complexes may be in a neutral or
charged state. The ligand to metal ratio may also vary, the exact
ratio being dependent on the nature of the ligand and metal-ligand
complex. The metal-ligand complex or complexes may take different
forms, for example, they may be monomeric, dimeric or of an even
higher order.
[0095] "Nonmetallocene" means that the metal of the catalyst is not
attached to a substituted or unsubstituted cyclopentadienyl ring.
Representative nonmetallocene, metal-centered, heteroarly ligand
catalysts are described in U.S. Provisional Patent Application Nos.
60/246,781 filed Nov. 7, 2000 and 60/301,666 filed Jun. 28,
2001.
[0096] As here used, "nonmetallocene, metal-centered, heteroaryl
ligand catalyst" means the catalyst derived from the ligand
described in formula I. As used in this phrase, "heteroaryl"
includes substituted heteroaryl.
[0097] As used herein, the phrase "characterized by the formula" is
not intended to be limiting and is used in the same way that
"comprising" is commonly used. The term "independently selected" is
used herein to indicate that the R groups, e.g., R.sup.1, R.sup.2,
R.sup.3, R.sup.4, and R.sup.5 can be identical or different (e.g.
R.sup.1, R.sup.2, R.sup.3, R.sup.4, and R.sup.5 may all be
substituted alkyls or R.sup.1 and R.sup.2 may be a substituted
alkyl and R.sup.3 may be an aryl, etc.). Use of the singular
includes use of the plural and vice versa (e.g., a hexane solvent,
includes hexanes). A named R group will generally have the
structure that is recognized in the art as corresponding to R
groups having that name. The terms "compound" and "complex" are
generally used interchangeably in this specification, but those of
skill in the art may recognize certain compounds as complexes and
vice versa. For the purposes of illustration, representative
certain groups are defined herein. These definitions are intended
to supplement and illustrate, not preclude, the definitions known
to those of skill in the art.
[0098] "Hydrocarbyl" refers to univalent hydrocarbyl radicals
containing 1 to about 30 carbon atoms, preferably 1 to about 24
carbon atoms, most preferably 1 to about 12 carbon atoms, including
branched or unbranched, saturated or unsaturated species, such as
alkyl groups, alkenyl groups, aryl groups, and the like.
"Substituted hydrocarbyl" refers to hydrocarbyl substituted with
one or more substituent groups, and the terms
"heteroatom-containing hydrocarbyl" and "heterohydrocarbyl" refer
to hydrocarbyl in which at least one carbon atom is replaced with a
heteroatom.
[0099] The term "alkyl" is used herein to refer to a branched or
unbranched, saturated or unsaturated acyclic hydrocarbon radical.
Suitable alkyl radicals include, for example, methyl, ethyl,
n-propyl, i-propyl, 2-propenyl (or allyl), vinyl, n-butyl, t-butyl,
i-butyl (or 2-methylpropyl), etc. In particular embodiments, alkyls
have between 1 and 200 carbon atoms, between 1 and 50 carbon atoms
or between 1 and 20 carbon atoms.
[0100] "Substituted alkyl" refers to an alkyl as just described in
which one or more hydrogen atom bound to any carbon of the alkyl is
replaced by another group such as a halogen, aryl, substituted
aryl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl,
substituted heterocycloalkyl, halogen, alkylhalos (e.g., CF.sub.3),
hydroxy, amino, phosphido, alkoxy, amino, thio, nitro, and
combinations thereof. Suitable substituted alkyls include, for
example, benzyl, trifluoromethyl and the like.
[0101] The term "heteroalkyl" refers to an alkyl as described above
in which one or more carbon atoms to any carbon of the alkyl is
replaced by a heteroatom selected from the group consisting of N,
O, P, B, S, Si, Sb, Al, Sn, As, Se and Ge. This same list of
heteroatoms is useful throughout this specification. The bond
between the carbon atom and the heteroatom may be saturated or
unsaturated. Thus, an alkyl substituted with a heterocycloalkyl,
substituted heterocycloalkyl, heteroaryl, substituted heteroaryl,
alkoxy, aryloxy, boryl, phosphino, amino, silyl, thio, or seleno is
within the scope of the term heteroalkyl. Suitable heteroalkyls
include cyano, benzoyl, 2-pyridyl, 2-furyl and the like.
[0102] The term "cycloalkyl" is used herein to refer to a saturated
or unsaturated cyclic non-aromatic hydrocarbon radical having a
single ring or multiple condensed rings. Suitable cycloalkyl
radicals include, for example, cyclopentyl, cyclohexyl,
cyclooctenyl, bicyclooctyl, etc. In particular embodiments,
cycloalkyls have between 3 and 200 carbon atoms, between 3 and 50
carbon atoms or between 3 and 20 carbon atoms.
[0103] "Substituted cycloalkyl" refers to cycloalkyl as just
described including in which one or more hydrogen atom to any
carbon of the cycloalkyl is replaced by another group such as a
halogen, alkyl, substituted alkyl, aryl, substituted aryl,
cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted
heterocycloalkyl, heteroaryl, substituted heteroaryl, alkoxy,
aryloxy, boryl, phosphino, amino, silyl, thio, seleno and
combinations thereof. Suitable substituted cycloalkyl radicals
include, for example, 4-dimethylaminocyclohexyl,
4,5-dibromocyclohept-4-enyl, and the like.
[0104] The term "heterocycloalkyl" is used herein to refer to a
cycloalkyl radical as described, but in which one or more or all
carbon atoms of the saturated or unsaturated cyclic radical are
replaced by a heteroatom such as nitrogen, phosphorous, oxygen,
sulfur, silicon, germanium, selenium, or boron. Suitable
heterocycloalkyls include, for example, piperazinyl, morpholinyl,
tetrahydropyranyl, tetrahydrofuranyl, piperidinyl, pyrrolidinyl,
oxazolinyl and the like.
[0105] "Substituted heterocycloalkyl" refers to heterocycloalkyl as
just described including in which one or more hydrogen atom to any
atom of the heterocycloalkyl is replaced by another group such as a
halogen, alkyl, substituted alkyl, aryl, substituted aryl,
heteroaryl, substituted heteroaryl, alkoxy, aryloxy, boryl,
phosphino, amino, silyl, thio, seleno and combinations thereof.
Suitable substituted heterocycloalkyl radicals include, for
example, N-methylpiperazinyl, 3-dimethylaminomorpholinyl and the
like.
[0106] The term "aryl" is used herein to refer to an aromatic
substituent which may be a single aromatic ring or multiple
aromatic rings which are fused together, linked covalently, or
linked to a common group such as a methylene or ethylene moiety.
The aromatic ring(s) may include phenyl, naphthyl, anthracenyl, and
biphenyl, among others. In particular embodiments, aryls have
between 1 and 200 carbon atoms, between 1 and 50 carbon atoms or
between 1 and 20 carbon atoms.
[0107] "Substituted aryl" refers to aryl as just described in which
one or more hydrogen atom bound to any carbon is replaced by one or
more functional groups such as alkyl, substituted alkyl,
cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted
heterocycloalkyl, halogen, alkylhalos (e.g., CF.sub.3), hydroxy,
amino, phosphido, alkoxy, amino, thio, nitro, and both saturated
and unsaturated cyclic hydrocarbons which are fused to the aromatic
ring(s), linked covalently or linked to a common group such as a
methylene or ethylene moiety. The common linking group may also be
a carbonyl as in benzophenone or oxygen as in diphenylether or
nitrogen in diphenylamine.
[0108] The term "heteroaryl" as used herein refers to aromatic or
unsaturated rings in which one or more carbon atoms of the aromatic
ring(s) are replaced by a heteroatom(s) such as nitrogen, oxygen,
boron, selenium, phosphorus, silicon or sulfur. Heteroaryl refers
to structures that may be a single aromatic ring, multiple aromatic
ring(s), or one or more aromatic rings coupled to one or more
non-aromatic ring(s). In structures having multiple rings, the
rings can be fused together, linked covalently, or linked to a
common group such as a methylene or ethylene moiety. The common
linking group may also be a carbonyl as in phenyl pyridyl ketone.
As used herein, rings such as thiophene, pyridine, isoxazole,
pyrazole, pyrrole, furan, etc. or benzo-fused analogues of these
rings are defined by the term "heteroaryl."
[0109] "Substituted heteroaryl" refers to heteroaryl as just
described including in which one or more hydrogen atoms bound to
any atom of the heteroaryl moiety is replaced by another group such
as a halogen, alkyl, substituted alkyl, aryl, substituted aryl,
heteroaryl, substituted heteroaryl, alkoxy, aryloxy, boryl,
phosphino, amino, silyl, thio, seleno and combinations thereof.
Suitable substituted heteroaryl radicals include, for example,
4-N,N-dimethylaminopyridine.
[0110] The term "alkoxy" is used herein to refer to the --OZ.sup.1
radical, where Z.sup.1 is selected from the group consisting of
alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl,
heterocycloalkyl, substituted heterocycloalkyl, silyl groups and
combinations thereof as described herein. Suitable alkoxy radicals
include, for example, methoxy, ethoxy, benzyloxy, t-butoxy, etc. A
related term is "aryloxy" where Z.sup.1 is selected from the group
consisting of aryl, substituted aryl, heteroaryl, substituted
heteroaryl, and combinations thereof. Examples of suitable aryloxy
radicals include phenoxy, substituted phenoxy, 2-pyridinoxy,
8-quinalinoxy and the like.
[0111] As used herein the term "silyl" refers to the
--SiZ.sup.1Z.sup.2Z.sup.3 radical, where each of Z.sup.1, Z.sup.2,
and Z.sup.3 is independently selected from the group consisting of
hydrogen, alkyl, substituted alkyl, cycloalkyl, heterocycloalkyl,
heterocyclic, aryl, substituted aryl, heteroaryl, substituted
heteroaryl, alkoxy, aryloxy, amino, silyl and combinations
thereof.
[0112] As used herein the term "boryl" refers to the
--BZ.sup.1Z.sup.2 group, where each of Z.sup.1 and Z.sup.2 is
independently selected from the group consisting of hydrogen,
alkyl, substituted alkyl, cycloalkyl, heterocycloalkyl,
heterocyclic, aryl, substituted aryl, heteroaryl, substituted
heteroaryl, alkoxy, aryloxy, amino, silyl and combinations
thereof.
[0113] As used herein, the term "phosphino" refers to the group
--PZ.sup.1Z.sup.2, where each of Z.sup.1 and Z.sup.2 is
independently selected from the group consisting of hydrogen,
substituted or unsubstituted alkyl, cycloalkyl, heterocycloalkyl,
heterocyclic, aryl, substituted aryl, heteroaryl, silyl, alkoxy,
aryloxy, amino and combinations thereof.
[0114] As used herein, the term "phosphine" refers to the group
:PZ.sup.1Z.sup.2Z.sup.3, where each of Z.sup.1, Z.sup.3 and Z.sup.2
is independently selected from the group consisting of hydrogen,
substituted or unsubstituted alkyl, cycloalkyl, heterocycloalkyl,
heterocyclic, aryl, substituted aryl, heteroaryl, silyl, alkoxy,
aryloxy, amino and combinations thereof.
[0115] The term "amino" is used herein to refer to the group
--NZ.sup.1Z.sup.2, where each of Z.sup.1 and Z.sup.2 is
independently selected from the group consisting of hydrogen,
alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl,
heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted
aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl
and combinations thereof.
[0116] The term "amine" is used herein to refer to the group
:NZ.sup.1Z.sup.2Z.sup.3, where each of Z.sup.1, Z.sup.2 and Z.sup.2
is independently selected from the group consisting of hydrogen,
alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl,
heterocycloalkyl, substituted heterocycloalkyl, aryl (including
pyridines), substituted aryl, heteroaryl, substituted heteroaryl,
alkoxy, aryloxy, silyl and combinations thereof.
[0117] The term "thio" is used herein to refer to the group
--SZ.sup.1, where Z.sup.1 is selected from the group consisting of
hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted
cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl,
substituted aryl, heteroaryl, substituted heteroaryl, alkoxy,
aryloxy, silyl and combinations thereof.
[0118] The term "seleno" is used herein to refer to the group
--SeZ.sup.1, where Z.sup.1 is selected from the group consisting of
hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted
cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl,
substituted aryl, heteroaryl, substituted heteroaryl, alkoxy,
aryloxy, silyl and combinations thereof.
[0119] The term "saturated" refers to lack of double and triple
bonds between atoms of a radical group such as ethyl, cyclohexyl,
pyrrolidinyl, and the like.
[0120] The term "unsaturated" refers to the presence one or more
double and/or triple bonds between atoms of a radical group such as
vinyl, acetylide, oxazolinyl, cyclohexenyl, acetyl and the
like.
Ligands
[0121] Suitable ligands useful in the catalysts used to make the P*
and P/E* polymers used in the practice of this invention can be
characterized broadly as monoanionic ligands having an amine and a
heteroaryl or substituted heteroaryl group. The ligands of these
catalysts are referred to, for the purposes of this invention, as
nonmetallocene ligands, and may be characterized by the following
general formula: ##STR1## wherein R.sup.1 is very generally
selected from the group consisting of alkyl, substituted alkyl,
cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted
heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl,
substituted aryl, heteroaryl, substituted heteroaryl and
combinations thereof. In many embodiments, R.sup.1 is a ring having
from 4-8 atoms in the ring generally selected from the group
consisting of substituted cycloalkyl, substituted heterocycloalkyl,
substituted aryl and substituted heteroaryl, such that R.sup.1 may
be characterized by the general formula: ##STR2## where Q.sup.1 and
Q.sup.5 are substituents on the ring ortho to atom E, with E being
selected from the group consisting of carbon and nitrogen and with
at least one of Q.sup.1 or Q.sup.5 being bulky (defined as having
at least 2 atoms). Q.sup.1 and Q.sup.5 are independently selected
from the group consisting of alkyl, substituted alkyl, cycloalkyl,
substituted cycloalkyl, aryl, substituted aryl and silyl, but
provided that Q.sup.1 and Q.sup.5 are not both methyl. Q''.sub.q
represents additional possible substituents on the ring, with q
being 1, 2, 3, 4 or 5 and Q'' being selected from the group
consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl,
substituted cycloalkyl, heteroalkyl, substituted heteroalkyl,
heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted
aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl,
boryl, phosphino, amino, thio, seleno, halide, nitro, and
combinations thereof. T is a bridging group selected group
consisting of --CR.sup.2R.sup.3-- and --SiR.sup.2R.sup.3-- with
R.sup.2 and R.sup.3 being independently selected from the group
consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl,
substituted cycloalkyl, heteroalkyl, substituted heteroalkyl,
heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted
aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl,
boryl, phosphino, amino, thio, seleno, halide, nitro, and
combinations thereof. J'' is generally selected from the group
consisting of heteroaryl and substituted heteroaryl, with
particular embodiments for particular reactions being described
herein.
[0122] In a more specific embodiment, suitable nonmetallocene
ligands may be characterized by the following general formula:
##STR3## wherein R.sup.1 and T are as defined above and each of
R.sup.4, R.sup.5, R.sup.6 and R.sup.7 is independently selected
from the group consisting of hydrogen, alkyl, substituted alkyl,
cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted
heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl,
substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl,
aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide,
nitro, and combinations thereof. Optionally, any combination of
R.sup.1, R.sup.2, R.sup.3 and R.sup.4 may be joined together in a
ring structure.
[0123] In certain more specific embodiments, the ligands may be
characterized by the following general formula: ##STR4## wherein
Q.sup.1, Q.sup.5, R.sup.2, R.sup.3, R.sup.4, R.sup.5, R.sup.6 and
R.sup.7 are as defined above. Q.sup.2, Q.sup.3 and Q.sup.4 are
independently selected from the group consisting of hydrogen,
alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl,
heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted
heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted
heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino,
thio, seleno, nitro, and combinations thereof.
[0124] In other more specific embodiments, the suitable ligands may
be characterized by the following general formula: ##STR5## wherein
R.sup.1, R.sup.2, R.sup.3, R.sup.4, R.sup.5, and R.sup.6 are as
defined above. In this embodiment the R.sup.7 substituent has been
replaced with an aryl or substituted aryl group, with R.sup.10,
R.sup.11, R.sup.12 and R.sup.13 being independently selected from
the group consisting of hydrogen, halo, alkyl, substituted alkyl,
cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted
heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl,
substituted aryl, heteroaryl, substituted heteroaryl, alkoxy,
aryloxy, silyl, boryl, phosphino, amino, thio, seleno, nitro, and
combinations thereof, optionally, two or more R.sup.10, R.sup.11,
R.sup.12 and R.sup.13 groups may be joined to form a fused ring
system having from 3-50 non-hydrogen atoms. R.sup.14 is selected
from the group consisting of hydrogen, alkyl, substituted alkyl,
cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted
heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl,
substituted aryl, heteroaryl, substituted heteroaryl, alkoxy,
aryloxy, silyl, boryl, phosphino, amino, thio, seleno, halide,
nitro, and combinations thereof.
[0125] In still more specific embodiments, the ligands may be
characterized by the general formula: ##STR6## wherein
R.sup.2-R.sup.6, R.sup.10-R.sup.14 and Q.sup.1-Q.sup.5 are all as
defined above.
[0126] In certain embodiments, R.sup.2 is preferably hydrogen. Also
preferably, each of R.sup.4 and R.sup.5 is hydrogen and R.sup.6 is
either hydrogen or is joined to R.sup.7 to form a fused ring
system. Also preferred is where R.sup.3 is selected from the group
consisting of benzyl, phenyl, 2-biphenyl, t-butyl,
2-dimethylaminophenyl
(2-(NMe.sub.2)--C.sub.6H.sub.4--),2-methoxyphenyl
(2-MeO--C.sub.6H.sub.4--), anthracenyl, mesityl, 2-pyridyl,
3,5-dimethylphenyl, o-tolyl, 9-phenanthrenyl. Also preferred is
where R.sup.1 is selected from the group consisting of mesityl,
4-isopropylphenyl (4-Pr.sup.i--C.sub.6H.sub.4--), napthyl,
3,5-(CF.sub.3).sub.2--C.sub.6H.sub.3--, 2-Me-napthyl,
2,6-(Pr.sup.i).sub.2--C.sub.6H.sub.3--, 2-biphenyl,
2-Me-4-MeO--C.sub.6H.sub.3--; 2-Bu.sup.t-C.sub.6H.sub.4--,
2,5-(Bu.sup.t).sub.2--C.sub.6H.sub.3--,
2-Pr.sup.i-6-Me--C.sub.6H.sub.3--;
2-Bu.sup.t-6-Me--C.sub.6H.sub.3--, 2,6-Et.sub.2-C.sub.6H.sub.3--,
2-sec-butyl-6-Et-C.sub.6H.sub.3-- Also preferred is where R.sup.7
is selected from the group consisting of hydrogen, phenyl, napthyl,
methyl, anthracenyl, 9-phenanthrenyl, mesityl,
3,5-(CF.sub.3).sub.2--C.sub.6H.sub.3--,
2-CF.sub.3--C.sub.6H.sub.4--, 4-CF.sub.3--C.sub.6H.sub.4--,
3,5-F.sub.2--C.sub.6H.sub.3--, 4-F--C.sub.6H.sub.4--,
2,4-F.sub.2--C.sub.6H.sub.3--, 4-(NMe.sub.2)-C.sub.6H.sub.4--,
3-MeO--C.sub.6H.sub.4--, 4-MeO--C.sub.6H.sub.4--,
3,5-Me.sub.2--C.sub.6H.sub.3--, o-tolyl,
2,6-F.sub.2--C.sub.6H.sub.3-- or where R.sup.7is joined together
with R.sup.6 to form a fused ring system, e.g., quinoline.
[0127] Also optionally, two or more R.sup.4, R.sup.5, R.sup.6,
R.sup.7 groups may be joined to form a fused ring system having
from 3-50 non-hydrogen atoms in addition to the pyridine ring, e.g.
generating a quinoline group. In these embodiments, R.sup.3 is
selected from the group consisting of aryl, substituted aryl,
heteroaryl, substituted heteroaryl, primary and secondary alkyl
groups, and --PY.sub.2 where Y is selected from the group
consisting of aryl, substituted aryl, heteroaryl, and substituted
heteroaryl.
[0128] Optionally within above formulas IV and V, R.sup.6 and
R.sup.10 may be joined to form a ring system having from 5-50
non-hydrogen atoms. For example, if R.sup.6 and R.sup.10 together
form a methylene, the ring will have 5 atoms in the backbone of the
ring, which may or may not be substituted with other atoms. Also
for example, if R.sup.6 and R.sup.10 together form an ethylene, the
ring will have 6 atoms in the backbone of the ring, which may or
may not be substituted with other atoms. Substituents from the ring
can be selected from the group consisting of halo, alkyl,
substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl,
substituted heteroalkyl, heterocycloalkyl, substituted
heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted
heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio,
seleno, nitro, and combinations thereof.
[0129] In certain embodiments, the ligands are novel compounds. One
example of the novel ligand compounds, includes those compounds
generally characterized by formula (III), above where R.sup.2 is
selected from the group consisting of hydrogen, alkyl, substituted
alkyl, cycloalkyl, substituted cycloalkyl, aryl, and substituted
aryl; and R.sup.3 is a phosphino characterized by the formula
--PZ.sup.1Z.sup.2, where each of Z.sup.1 and Z.sup.2 is
independently selected from the group consisting of hydrogen,
substituted or unsubstituted alkyl, cycloalkyl, heterocycloalkyl,
heterocyclic, aryl, substituted aryl, heteroaryl, silyl, alkoxy,
aryloxy, amino and combinations thereof. Particularly preferred
embodiments of these compounds include those where Z.sup.1 and
Z.sup.2 are each independently selected from the group consisting
of alkyl, substituted alkyl, cycloalkyl, heterocycloalkyl, aryl,
and substituted aryl; and more specifically phenyl; where Q.sup.1,
Q.sup.3, and Q.sup.5 are each selected from the group consisting of
alkyl and substituted alkyl and each of Q.sup.2 and Q.sup.4 is
hydrogen; and where R.sup.4, R.sup.5, R.sup.6 and R.sup.7 are each
hydrogen.
[0130] The ligands may be prepared using known procedures. See, for
example, Advanced Organic Chemistry, March, Wiley, New York 1992
(4.sup.th Ed.). Specifically, the ligands of the invention may be
prepared using the two step procedure outlined in Scheme 1.
##STR7##
[0131] In Scheme 1, the * represents a chiral center when R.sup.2
and R.sup.3 are not identical; also, the R groups have the same
definitions as above. Generally, R.sup.3M.sup.2 is a nucleophile
such as an alkylating or arylating or hydrogenating reagent and
M.sup.2 is a metal such as a main group metal, or a metalloid such
as boron. The alkylating, arylating or hydrogenating reagent may be
a Grignard, alkyl, aryl-lithium or borohydride reagent. Scheme 1,
step 2 first employs the use of complexing reagent. Preferably, as
in the case of Scheme 1, magnesium bromide is used as the
complexing reagent. The role of the complexing reagent is to direct
the nucleophile, R.sup.3M.sup.2, selectively to the imine carbon.
Where the presence of functional groups impede this synthetic
approach, alternative synthetic strategies may be employed. For
instance, ligands where R.sup.3=phosphino can be prepared in
accordance with the teachings of U.S. Pat. Nos. 6,034,240 and
6,043,363. In addition, tetra-alkylhafnium compounds or
tetra-substituted alkylhafnium compounds or tetra-arylhafnium
compounds or tetra-substituted arylhafnium compounds may be
employed in step 2, in accordance with the teachings of U.S. Pat.
No. 6,103,657. Scheme 2 further describes a synthesis process:
##STR8##
[0132] In scheme 2, h=1 or 2 and the bromine ions may or may not be
bound to the magnesium. The effect of the complexation is to guide
the subsequent nucleophilic attack by R.sup.3M.sup.2 to the imine
carbon. As shown in Scheme 2 by the *, where R.sup.2 and R.sup.3
are different, this approach also leads to the formation of a
chiral center on the ancillary ligands of the invention which
promotes resin tacitity. Under some circumstances R.sup.3M.sup.2
may be successfully added to the imine in the absence the
complexing reagent. Ancillary ligands that possess chirality may be
important in certain olefin polymerization reactions, particularly
those that lead to a stereospecific polymer, see "Stereospecific
Olefin Polymerization with Chiral Metallocene Catalysts",
Brintzinger, et al., Angew. Chem. Int. Ed. Engl., 1995, Vol. 34,
pp. 1143-1170, and the references therein; Bercaw et al., J. Am.
Chem. Soc., 1999, Vol. 121, 564-573; and Bercaw et al., J. Am.
Chem. Soc., 1996, Vol. 118, 11988-11989.
Compositions
[0133] Once the desired ligand is formed, it may be combined with a
metal atom, ion, compound or other metal precursor compound. In
some applications, the ligands will be combined with a metal
compound or precursor and the product of such combination is not
determined, if a product forms. For example, the ligand may be
added to a reaction vessel at the same time as the metal or metal
precursor compound along with the reactants, activators,
scavengers, etc. Additionally, the ligand can be modified prior to
addition to or after the addition of the metal precursor, e.g.
through a deprotonation reaction or some other modification.
[0134] For formulas I, II, III, IV and V, the metal precursor
compounds may be characterized by the general formula Hf(L).sub.n
where L is independently selected from the group consisting of
halide (F, Cl, Br, I), alkyl, substituted alkyl, cycloalkyl,
substituted cycloalkyl, heteroalkyl, substituted heteroalkyl,
heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted
aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy,
boryl, silyl, amino, amine, hydrido, allyl, diene, seleno,
phosphino, phosphine, carboxylates, thio, 1,3-dionates, oxalates,
carbonates, nitrates, sulphates, and combinations thereof. n is 1,
2, 3, 4, 5, or 6. The hafnium precursors may be monomeric, dimeric
or higher orders thereof. It is well known that hafnium metal
typically contains some amount of impurity of zirconium. Thus, this
invention uses as pure hafnium as is commercially reasonable.
Specific examples of suitable hafnium precursors include, but are
not limited to HfCl.sub.4, Hf(CH.sub.2Ph).sub.4,
Hf(CH.sub.2CMe.sub.3).sub.4, Hf(CH.sub.2SiMe.sub.3).sub.4,
Hf(CH.sub.2Ph).sub.3Cl, Hf(CH.sub.2CMe.sub.3).sub.3Cl,
Hf(CH.sub.2SiMe.sub.3).sub.3Cl, Hf(CH.sub.2Ph).sub.2Cl.sub.2,
Hf(CH.sub.2CMe.sub.3).sub.2Cl.sub.2,
Hf(CH.sub.2SiMe.sub.3).sub.2Cl.sub.2, Hf(NMe.sub.2).sub.4,
Hf(NEt.sub.2).sub.4, and Hf(N(SiMe.sub.3).sub.2).sub.2Cl.sub.2.
Lewis base adducts of these examples are also suitable as hafnium
precursors, for example, ethers, amines, thioethers, phosphines and
the like are suitable as Lewis bases.
[0135] For formulas IV and V, the metal precursor compounds may be
characterized by the general formula M(L).sub.n where M is hafnium
or zirconium and each L is independently selected from the group
consisting of halide (F, Cl, Br, I), alkyl, substituted alkyl,
cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted
heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl,
substituted aryl, heteroaryl, substituted heteroaryl, alkoxy,
aryloxy, hydroxy, boryl, silyl, amino, amine, hydrido, allyl,
diene, seleno, phosphino, phosphine, carboxylates, thio,
1,3-dionates, oxalates, carbonates, nitrates, sulphates, and
combinations thereof. n is 4, typically. It is well known that
hafnium metal typically contains some amount of impurity of
zirconium. Thus, this practice uses as pure hafnium or zirconium as
is commercially reasonable. Specific examples of suitable hafnium
and zirconium precursors include, but are not limited to
HfCl.sub.4, Hf(CH.sub.2Ph).sub.4, Hf(CH.sub.2CMe.sub.3).sub.4,
Hf(CH.sub.2SiMe.sub.3).sub.4, Hf(CH.sub.2Ph).sub.3Cl,
Hf(CH.sub.2CMe.sub.3).sub.3Cl, Hf(CH.sub.2SiMe.sub.3).sub.3Cl,
Hf(CH.sub.2Ph).sub.2Cl.sub.2, Hf(CH.sub.2CMe.sub.3).sub.2Cl.sub.2,
Hf(CH.sub.2SiMe.sub.3).sub.2Cl.sub.2, Hf(NMe.sub.2).sub.4,
Hf(NEt.sub.2).sub.4, and Hf(N(SiMe.sub.3).sub.2).sub.2Cl.sub.2;
ZrCl.sub.4, Zr(CH.sub.2Ph).sub.4, Zr(CH.sub.2CMe.sub.3).sub.4,
Zr(CH.sub.2SiMe.sub.3).sub.4, Zr(CH.sub.2Ph).sub.3Cl,
Zr(CH.sub.2CMe.sub.3).sub.3Cl, Zr(CH.sub.2SiMe.sub.3).sub.3Cl,
Zr(CH.sub.2Ph).sub.2Cl.sub.2, Zr(CH.sub.2CMe.sub.3).sub.2Cl.sub.2,
Zr(CH.sub.2SiMe.sub.3).sub.2Cl.sub.2, Zr(NMe.sub.2).sub.4,
Zr(NEt.sub.2).sub.4, Zr(NMe.sub.2).sub.2Cl.sub.2,
Zr(NEt.sub.2).sub.2Cl.sub.2, and
Zr(N(SiMe.sub.3).sub.2).sub.2Cl.sub.2. Lewis base adducts of these
examples are also suitable as hafnium precursors, for example,
ethers, amines, thioethers, phosphines and the like are suitable as
Lewis bases.
[0136] The ligand to metal precursor compound ratio is typically in
the range of about 0.01:1 to about 100:1, more preferably in the
range of about 0.1:1 to about 10:1.
Metal-Ligand Complexes
[0137] Generally, the ligand is mixed with a suitable metal
precursor compound prior to or simultaneously with allowing the
mixture to be contacted with the reactants (e.g., monomers). When
the ligand is mixed with the metal precursor compound, a
metal-ligand complex may be formed, which may be a catalyst or may
need to be activated to be a catalyst. The metal-ligand complexes
discussed herein are referred to as 2,1 complexes or 3,2 complexes,
with the first number representing the number of coordinating atoms
and second number representing the charge occupied on the metal.
The 2,1-complexes therefore have two coordinating atoms and a
single anionic charge. Other embodiments are those complexes that
have a general 3,2 coordination scheme to a metal center, with 3,2
referring to a ligand that occupies three coordination sites on the
metal and two of those sites being anionic and the remaining site
being a neutral Lewis base type coordination.
[0138] Looking first at the 2,1-nonmetallocene metal-ligand
complexes, the metal-ligand complexes may be characterized by the
following general formula: ##STR9## wherein T, J'', R.sup.1, L and
n are as defined previously; and x is 1 or 2. The J'' heteroaryl
may or may not datively bond, but is drawn as bonding. More
specifically, the nonmetallocene-ligand complexes may be
characterized by the formula: ##STR10## wherein R.sup.1, T,
R.sup.4, R.sup.5, R.sup.6, R.sup.7, L and n are as defined
previously; and x is 1 or 2. In one preferred embodiment x=1 and
n=3. Additionally, Lewis base adducts of these metal-ligand
complexes can also be used, for example, ethers, amines,
thioethers, phosphines and the like are suitable as Lewis
bases.
[0139] More specifically, the nonmetallocene metal-ligand complexes
may be characterized by the general formula: ##STR11## wherein the
variables are generally defined above. Thus, e.g., Q.sup.2,
Q.sup.3, Q.sup.4, R.sup.2, R.sup.3, R.sup.4, R.sup.5, R.sup.6 and
R.sup.7 are independently selected from the group consisting of
hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted
cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl,
substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl,
substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino,
amino, thio, seleno, nitro, and combinations thereof, optionally,
two or more R.sup.4, R.sup.5, R.sup.6, R.sup.7 groups may be joined
to form a fused ring system having from 3-50 non-hydrogen atoms in
addition to the pyridine ring, e.g. generating a quinoline group;
also, optionally, any combination of R.sup.2, R.sup.3 and R.sup.4
may be joined together in a ring structure; Q.sup.1 and Q.sup.5 are
selected from the group consisting of alkyl, substituted alkyl,
cycloalkyl, substituted cycloalkyl, aryl, substituted aryl,
provided that Q.sup.1 and Q.sup.5 are not both methyl; and each L
is independently selected from the group consisting of halide,
alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl,
heteroalkyl, substituted heteroalkyl heterocycloalkyl, substituted
heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted
heteroaryl, alkoxy, aryloxy, hydroxy, boryl, silyl, amino, amine,
hydrido, allyl, diene, seleno, phosphino, phosphine, carboxylates,
thio, 1,3-dionates, oxalates, carbonates, nitrates, sulphates and
combinations thereof; n is 1, 2, 3, 4, 5, or 6; and x=1 or 2.
[0140] In other embodiments, the 2,1 metal-ligand complexes can be
characterized by the general formula: ##STR12## wherein the
variables are generally defined above.
[0141] In still other embodiments, the 2,1 metal-ligand complexes
can be characterized by the general formula: ##STR13## wherein the
variables are generally defined above.
[0142] The more specific embodiments of the nonmetallocene
metal-ligand complexes of formulas VI, VII, VIII, IX and X are
explained above with regard to the specifics described for the
ligands and metal precursors. Specific examples of 2,1 metal-ligand
complexes include, but are not limited to: ##STR14## ##STR15##
##STR16## ##STR17## where L, n and x are defined as above (e.g.,
x=1 or 2) and Ph=phenyl. In preferred embodiments, x=1 and n=3.
Furthermore in preferred embodiments, L is selected from the group
consisting of alkyl, substituted alkyl, aryl, substituted aryl or
amino.
[0143] Turning to the 3,2 metal-ligand nonmetallocene complexes,
the metal-ligand complexes may be characterized by the general
formula: ##STR18##
[0144] where M is zirconium or hafnium;
[0145] R.sup.1 and T are defined above;
[0146] J''' being selected from the group of substituted
heteroaryls with 2 atoms bonded to the metal M, at least one of
those 2 atoms being a heteroatom, and with one atom of J''' is
bonded to M via a dative bond, the other through a covalent bond;
and
[0147] L.sup.1 and L.sup.2 are independently selected from the
group consisting of halide, alkyl, substituted alkyl, cycloalkyl,
substituted cycloalkyl, heteroalkyl, substituted heteroalkyl,
heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted
aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy,
boryl, silyl, amino, amine, hydrido, allyl, diene, seleno,
phosphino, phosphine, carboxylates, thio, 1,3-dionates, oxalates,
carbonates, nitrates, sulphates, and combinations thereof.
[0148] More specifically, the 3,2 metal-ligand nonmetallocene
complexes may be characterized by the general formula:
##STR19##
[0149] where M is zirconium or hafnium;
[0150] T, R.sup.1, R.sup.4, R.sup.5, R.sup.6, L.sup.1 and L.sup.2
are defined above; and
[0151] E'' is either carbon or nitrogen and is part of an cyclic
aryl, substituted aryl, heteroaryl, or substituted heteroaryl
group.
[0152] Even more specifically, the 3,2 metal-ligand nonmetallocene
complexes may be characterized by the general formula:
##STR20##
[0153] where M is zirconium or hafnium; and
[0154] T, R.sup.1, R.sup.4, R.sup.5, R.sup.6, R.sup.10, R.sup.11,
R.sup.12, R.sup.13, L.sup.1 and L.sup.2 are defined above.
[0155] Still even more specifically, the 3,2 metal-ligand
nonmetallocene complexes may be characterized by the general
formula: ##STR21##
[0156] where M is zirconium or hafnium; and
[0157] T, R.sup.1, R.sup.4, R.sup.5, R.sup.6, R.sup.10, R.sup.11,
R.sup.12, R.sup.13, Q.sup.1, Q.sup.2, Q.sup.3, Q.sup.4, Q.sup.5,
L.sup.1 and L.sup.2 are defined above.
[0158] The more specific embodiments of the metal-ligand complexes
of formulas XI, XII, XIII and XIV are explained above with regard
to the specifics described for the ligands and metal
precursors.
[0159] In the above formulas, R.sup.10, R.sup.11, R.sup.12 and
R.sup.13 are independently selected from the group consisting of
hydrogen, halo, alkyl, substituted alkyl, cycloalkyl, substituted
cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl,
substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl,
substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino,
amino, thio, seleno, nitro, and combinations thereof; optionally,
two or more R.sup.10, R.sup.11, R.sup.12 and R.sup.13 groups may be
joined to form a fused ring system having from 3-50 non-hydrogen
atoms.
[0160] In addition, Lewis base adducts of the metal-ligand
complexes in the above formulas are also suitable, for example,
ethers, amines, thioethers, phosphines and the like are suitable as
Lewis bases.
[0161] The metal-ligand complexes can be formed by techniques known
to those of skill in the art. In some embodiments, R.sup.14 is
hydrogen and the metal-ligand complexes are formed by a metallation
reaction (in situ or not) as shown below in scheme 3: ##STR22##
[0162] In scheme 3, R.sup.14 is hydrogen (but see above for the
full definition of R.sup.14 in other embodiments). The metallation
reaction to convert the 2,1-complex on the left to the 3,2 complex
on the right can occur via a number of mechanisms, likely depending
on the substituents chosen for L.sup.1, L.sup.2 and L.sup.3 and the
other substituents such as Q.sup.1-Q.sup.5, R.sup.2-R.sup.6,
R.sup.10 to R.sup.13. In one embodiment, when L.sup.1, L.sup.2 and
L.sup.3 are each N(CH.sub.3).sub.2, the reaction can proceed by
heating the 2,1 complex to a temperature above about 100.degree. C.
In this embodiment, it is believed that L.sup.1 and L.sup.2 remain
N(CH.sub.3).sub.2 in the 3,2 complex. In another embodiment where
L.sup.1, L.sup.2 and L.sup.3 are each N(CH.sub.3).sub.2, the
reaction can proceed by adding a group 13 reagent (as described
below) to the 2,1 complex at a suitable temperature (such as room
temperature). Preferably the group 13 reagent for this purpose is
di-isobutyl aluminum hydride, tri-isobutyl aluminum or trimethyl
aluminum. In this embodiment, L.sup.1 and L.sup.2 are typically
converted to the ligand (e.g., alkyl or hydride) stemming from the
group 13 reagent (e.g., from trimethyl aluminum, L.sup.1 and
L.sup.2 are each CH.sub.3 in the 3,2 complex). The 2,1 complex in
scheme 3 is formed by the methods discussed above.
[0163] In an alternative embodiment possibly outside the scope of
scheme 3, for isotactic polypropylene production, it is currently
preferred that R.sup.14 is either hydrogen or methyl.
[0164] Specific examples of 3,2 complexes include: ##STR23##
[0165] Various references disclose metal complexes that may appear
to be similar; see for example, U.S. Pat. Nos. 6,103,657 and
5,637,660. However, certain embodiments herein provide unexpectedly
improved polymerization performance (e.g., higher activity and/or
higher polymerization temperatures and/or higher comonomer
incorporation and/or crystalline polymers resulting from a high
degree of stereoselectivity during polymerization) relative to the
embodiments disclosed in those references. In particular, as shown
in certain of the examples herein, the activity of the hafnium
metal catalysts is far superior to that of the zirconium
catalysts.
[0166] The ligands, complexes or catalysts may be supported on an
organic or inorganic support. Suitable supports include silicas,
aluminas, clays, zeolites, magnesium chloride, polyethylene
glycols, polystyrenes, polyesters, polyamides, peptides and the
like. Polymeric supports may be cross-linked or not. Similarly, the
ligands, complexes or catalysts may be supported on similar
supports known to those of skill in the art. In addition, the
catalysts may be combined with other catalysts in a single reactor
and/or employed in a series of reactors (parallel or serial) in
order to form blends of polymer products. Supported catalysts
typically produce P/E*copolymers with an MWD larger than those
produce from unsupported catalysts, although these MWDs are
typically less about 6, preferably less than about 5 and more
preferably less than about 4.
[0167] The metal complexes are rendered catalytically active by
combination with an activating cocatalyst or by use of an
activating technique. Suitable activating cocatalysts include
neutral Lewis acids such as alumoxane (modified and unmodified),
C.sub.1-30 hydrocarbyl substituted Group 13 compounds, especially
tri(hydrocarbyl)aluminum- or tri(hydrocarbyl)boron compounds and
halogenated (including perhalogenated) derivatives thereof, having
from 1 to 10 carbons in each hydrocarbyl or halogenated hydrocarbyl
group, more especially perfluorinated tri(aryl)boron compounds, and
most especially tris(pentafluorophenyl)borane; nonpolymeric,
compatible, noncoordinating, ion forming compounds (including the
use of such compounds under oxidizing conditions), especially the
use of ammonium-, phosphonium-, oxonium-, carbonium-, silylium- or
sulfonium-salts of compatible, noncoordinating anions, or
ferrocenium salts of compatible, noncoordinating anions; bulk
electrolysis (explained in more detail hereinafter); and
combinations of the foregoing activating cocatalysts and
techniques. The foregoing activating cocatalysts and activating
techniques have been previously taught with respect to different
metal complexes in the following references: U.S. Pat. Nos.
5,153,157, 5,064,802, 5,721,185 and 5,350,723, and EP-A-277,003 and
-A-468,6.51 (equivalent to U.S. Ser. No. 07/547,718).
[0168] The alumoxane used as an activating cocatalyst is of the
formula (R.sup.4.sub.x(CH.sub.3).sub.yAlO).sub.n, in which R.sup.4
is a linear, branched or cyclic C.sub.1 to C.sub.6 hydrocarbyl, x
is from 0 to about 1, y is from about 1 to 0, and n is an integer
from about 3 to about 25, inclusive. The preferred alumoxane
components, referred to as modified methylaluminoxanes, are those
wherein R.sup.4 is a linear, branched or cyclic C.sub.3 to C.sub.9
hydrocarbyl, x is from about 0.15 to about 0.50, y is from about
0.85 to about 0.5 and n is an integer between 4 and 20, inclusive;
still more preferably, R.sup.4 is isobutyl, tertiary butyl or
n-octyl, x is from about 0.2 to about 0.4, y is from about 0.8 to
about 0.6 and n is an integer between 4 and 15, inclusive. Mixtures
of the above alumoxanes may also be employed.
[0169] Most preferably, the alumoxane is of the formula
(R.sup.4.sub.x(CH.sub.3).sub.yAlO).sub.n, wherein R.sup.4 is
isobutyl or tertiary butyl, x is about 0.25, y is about 0.75 and n
is from about 6 to about 8.
[0170] Particularly preferred alumoxanes are so-called modified
alumoxanes, preferably modified methylalumoxanes (MMAO), that are
completely soluble in alkane solvents, for example heptane, and may
include very little, if any, trialkylaluminum. A technique for
preparing such modified alumoxanes is disclosed in U.S. Pat. No.
5,041,584 (which is incorporated by reference). Alumoxanes useful
as an activating cocatalyst may also be made as disclosed in U.S.
Pat. Nos. 4,542,199; 4,544,762; 4,960,878; 5,015,749; 5,041,583 and
5,041,585. Various alumoxanes can be obtained from commercial
sources, for example, Akzo-Nobel Corporation, and include MMAO-3A,
MMAO-12, and PMAO-IP.
[0171] Combinations of neutral Lewis acids, especially the
combination of a trialkyl aluminum compound having from 1 to 4
carbons in each alkyl group and a halogenated tri(hydrocarbyl)boron
compound having from 1 to 10 carbons in each hydrocarbyl group,
especially tris(pentafluorophenyl)borane, and combinations of
neutral Lewis acids, especially tris(pentafluorophenyl)borane, with
nonpolymeric, compatible noncoordinating ion-forming compounds are
also useful activating cocatalysts.
[0172] Suitable ion forming compounds useful as cocatalysts
comprise a cation which is a Bronsted acid capable of donating a
proton, and a compatible, noncoordinating anion, A.sup.-. As used
herein, the term "noncoordinating" means an anion or substance
which either does not coordinate to the Group 4 metal containing
precursor complex and the catalytic derivative derived therefrom,
or which is only weakly coordinated to such complexes thereby
remaining sufficiently labile to be displaced by a neutral Lewis
base. A noncoordinating anion specifically refers to an anion which
when functioning as a charge balancing anion in a cationic metal
complex does not transfer an anionic substituent or fragment
thereof to said cation thereby forming neutral complexes.
"Compatible anions" are anions which are not degraded to neutrality
when the initially formed complex decomposes and are noninterfering
with desired subsequent polymerization or other uses of the
complex.
[0173] Preferred anions are those containing a single coordination
complex comprising a charge-bearing metal or metalloid core which
anion is capable of balancing the charge of the active catalyst
species (the metal cation) which may be formed when the two
components are combined. Also, said anion should be sufficiently
labile to be displaced by olefinic, diolefinic and acetylenically
unsaturated compounds or other neutral Lewis bases such as ethers
or nitrites. Suitable metals include, but are not limited to,
aluminum, gold and platinum. Suitable metalloids include, but are
not limited to, boron, phosphorus, and silicon. Compounds
containing anions which comprise coordination complexes containing
a single metal or metalloid atom are, of course, well known and
many, particularly such compounds containing a single boron atom in
the anion portion, are available commercially.
[0174] In one embodiment, the activating cocatalysts may be
represented by the following general formula:
[L*-H].sup.+.sub.d[A.sup.d-] wherein:
[0175] L* is a neutral Lewis base;
[0176] [L*-H].sup.+ is a Bronsted acid;
[0177] A.sup.d- is a noncoordinating, compatible anion having a
charge of d.sup.-, and
[0178] d is an integer from 1 to 3.
More preferably A.sup.d- corresponds to the formula:
[M'.sup.k+Q.sub.n'].sup.d- wherein:
[0179] k is an integer from 1 to 3;
[0180] n' is an integer from 2 to 6;
[0181] n'-k=d;
[0182] M' is an element selected from Group 13 of the Periodic
Table of the Elements; and
[0183] Q independently each occurrence is selected from hydride,
dialkylamido, halide, hydrocarbyl, hydrocarbyloxy,
halosubstituted-hydrocarbyl, halosubstituted hydrocarbyloxy, and
halo substituted silylhydrocarbyl radicals (including
perhalogenated hydrocarbyl-perhalogenated hydrocarbyloxy- and
perhalogenated silylhydrocarbyl radicals), said Q having up to 20
carbons with the proviso that in not more than one occurrence is Q
halide. Examples of suitable hydrocarbyloxide Q groups are
disclosed in U.S. Pat. No. 5,296,433.
[0184] In a more preferred embodiment, d is one, i. e., the counter
ion has a single negative charge and is A.sup.-. Activating
cocatalysts comprising boron which are particularly useful in the
preparation of the catalysts may be represented by the following
general formula: [L*-H].sup.+[BQ.sub.4].sup.- wherein:
[0185] [L*-H].sup.+ is as previously defined;
[0186] B is boron in an oxidation state of 3; and
[0187] Q is a hydrocarbyl-, hydrocarbyloxy-, fluorinated
hydrocarbyl-, fluorinated hydrocarbyloxy- or fluorinated
silylhydrocarbyl-group of up to 20 nonhydrogen atoms, with the
proviso that in not more than one occasion is Q hydrocarbyl. Most
preferably, Q is each occurrence a fluorinated aryl group,
especially, a pentafluorophenyl group.
[0188] Illustrative, but not limiting, examples of boron compounds
which may be used as an activating cocatalyst in the preparation of
the catalysts are tri-substituted ammonium salts such as:
[0189] triethylammonium tetraphenylborate,
[0190] N,N-dimethylanilinium tetraphenylborate,
[0191] tripropylammonium tetrakis(pentafluorophenyl) borate,
[0192] N,N-dimethylanilinium n-butyltris(pentafluorophenyl)
borate,
[0193] triethylammonium tetrakis(2,3,4,6-tetrafluorophenyl)
borate,
[0194] N,N-diethylanilinium tetrakis(2,3,4,6-tetrafluorophenyl)
borate, and
[0195] N,N-dimethyl-2,4,6-trimethylanilinium
tetrakis(2,3,4,6-tetrafluorophenyl) borate;
[0196] dialkyl ammonium salts such as:
[0197] di-(i-propyl)ammonium tetrakis(pentafluorophenyl) borate,
and
[0198] dicyclohexylammonium tetrakis(pentafluorophenyl) borate;
[0199] tri-substituted phosphonium salts such as:
[0200] triphenylphosphonium tetrakis(pentafluorophenyl) borate,
[0201] tri(o-tolyl)phosphonium tetrakis(pentafluorophenyl) borate,
and
[0202] tri(2,6-dimethylphenyl)phosphonium
tetrakis(pentafluorophenyl) borate;
[0203] di-substituted oxonium salts such as:
[0204] diphenyloxonium tetrakis(pentafluorophenyl) borate,
[0205] di(o-tolyl)oxonium tetrakis(pentafluorophenyl) borate,
and
[0206] di(2,6-dimethylphenyl)oxonium tetrakis(pentafluorophenyl)
borate;
[0207] di-substituted sulfonium salts such as:
[0208] diphenylsulfonium tetrakis(pentafluorophenyl) borate,
[0209] di(o-tolyl)sulfonium tetrakis(pentafluorophenyl) borate,
and
[0210] di(2,6-dimethylphenyl)sulfonium tetrakis(pentafluorophenyl)
borate.
Preferred [L*-H].sup.+ cations are N,N-dimethylanilinium and
tributylammonium.
[0211] Another suitable ion forming, activating cocatalyst
comprises a salt of a cationic oxidizing agent and a
noncoordinating, compatible anion represented by the formula:
(Ox.sup.e+).sub.d(A.sup.d-).sub.e wherein:
[0212] Ox.sup.e+ is a cationic oxidizing agent having a charge of
e.sup.+;
[0213] e is an integer from 1 to 3; and
[0214] A.sup.d- and d are as previously defined.
[0215] Examples of cationic oxidizing agents include: ferrocenium,
hydrocarbyl-substituted ferrocenium, Ag.sup.+, or Pb.sup.+2.
Preferred embodiments of A.sup.d- are those anions previously
defined with respect to the Bronsted acid containing activating
cocatalysts, especially tetrakis(pentafluorophenyl)borate.
[0216] Another suitable ion forming, activating cocatalyst
comprises a compound which is a salt of a carbenium ion and a
noncoordinating, compatible anion represented by the formula:
.COPYRGT..sup.+A.sup.- wherein:
[0217] .COPYRGT..sup.+ is a C.sub.1-20 carbenium ion; and
[0218] A.sup.- is as previously defined.
A preferred carbenium ion is the trityl cation, i.e.,
triphenylmethylium.
[0219] A further suitable ion forming, activating cocatalyst
comprises a compound which is a salt of a silylium ion and a
noncoordinating, compatible anion represented by the formula:
R.sub.3Si(X').sub.q.sup.+A.sup.- wherein:
[0220] R is C.sub.1-10 hydrocarbyl, and X', q and A.sup.- are as
previously defined.
[0221] Preferred silylium salt activating cocatalysts are
trimethylsilylium tetrakis(pentafluorophenyl)borate,
triethylsilylium(tetrakispentafluoro)phenylborate and ether
substituted adducts thereof. Silylium salts have been previously
generically disclosed in J. Chem Soc. Chem. Comm., 1993, 383-384,
as well as Lambert, J. B., et al., Organometallics, 1994, 13,
2430-2443.
[0222] Certain complexes of alcohols, mercaptans, silanols, and
oximes with tris(pentafluorophenyl)borane are also effective
catalyst activators and may be used according to the present
invention. Such cocatalysts are disclosed in U.S. Pat. No.
5,296,433.
[0223] The metal complexes can also be activated by technique of
bulk electrolysis which involves the electrochemical oxidation of
the metal complex under electrolysis conditions in the presence of
a supporting electrolyte comprising a noncoordinating, inert anion.
A further discovered electrochemical technique for generation of
activating cocatalysts is the electrolysis of a disilane compound
in the presence of a source of a noncoordinating compatible anion.
This technique is more fully disclosed and claimed in U.S. Pat. No.
5,625,087.
[0224] The foregoing activating techniques and ion forming
cocatalysts are also preferably used in combination with a
tri(hydrocarbyl)aluminum or tri(hydrocarbyl)borane compound having
from 1 to 4 carbons in each hydrocarbyl group.
[0225] The molar ratio of catalyst/cocatalyst employed preferably
ranges from 1:10,000 to 100:1, more preferably from 1:5000 to 10:1,
most preferably from 1:100 to 1:1. In one embodiment the cocatalyst
can be used in combination with a tri(hydrocarbyl)aluminum compound
having from 1 to 10 carbons in each hydrocarbyl group. Mixtures of
activating cocatalysts may also be employed. It is possible to
employ these aluminum compounds for their beneficial ability to
scavenge impurities such as oxygen, water, and aldehydes from the
polymerization mixture. Preferred aluminum compounds include
trialkyl aluminum compounds having from 1 to 6 carbons in each
alkyl group, especially those wherein the alkyl groups are methyl,
ethyl, propyl, isopropyl, n-butyl, isobutyl, pentyl, neopentyl or
isopentyl. The molar ratio of metal complex to aluminum compound is
preferably from 1:10,000 to 100:1, more preferably from 1:1000 to
10:1, most preferably from 1:500 to 1:1. A most preferred borane
activating cocatalyst comprises a strong Lewis acid, especially
tris(pentafluorophenyl)borane.
[0226] In some embodiments, two or more different catalysts,
including the use of mixed catalysts can be employed. In addition
to a nonmetallocene, metal-centered, heteroaryl ligand catalyst,
when a plurality of catalysts are used, any catalyst which is
capable of copolymerizing one or more olefin monomers to make an
interpolymer or homopolymer may be used in embodiments of the
invention in conjunction with a nonmetallocene, metal-centered,
heteroaryl ligand catalyst. For certain embodiments, additional
selection criteria, such as molecular weight capability and/or
comonomer incorporation capability, preferably should be satisfied.
Two or more nonmetallocene, metal-centered, heteroaryl ligand
catalysts having different substituents can be used in the practice
of certain of the embodiments disclosed herein. Suitable catalysts
which may be used in conjunction with the nonmetallocene,
metal-centered, heteroaryl ligand catalysts disclosed herein
include, but are not limited to, Ziegler-Natta, metallocene and
constrained geometry catalysts and variations on one or more of
these. They include any known and presently unknown catalysts for
olefin polymerization. It should be understood that the term
"catalyst" as used herein refers to a metal-containing compound
which is used, along with an activating cocatalyst, to form a
catalyst system. The catalyst, as used herein, is usually
catalytically inactive in the absence of a cocatalyst or other
activating technique. However, not all suitable catalysts are
catalytically inactive without a cocatalyst.
[0227] One suitable class of catalysts is the constrained geometry
catalysts disclosed in U.S. Pat. Nos. 5,064,802, 5,132,380,
5,703,187 and 6,034,021; EP 0 468 651 and 0 514 828; and WO
93/19104 and 95/00526. Another suitable class of catalysts is the
metallocene catalysts disclosed in U.S. Pat. Nos. 5,044,438,
5,057,475, 5,096,867 and 5,324,800. The constrained geometry
catalysts may be considered as metallocene catalysts, and both are
sometimes referred to in the art as single-site catalysts.
[0228] Another suitable class of catalysts is substituted indenyl
containing metal complexes as disclosed in U.S. Pat. Nos. 5,965,756
and 6,015,868. Other catalysts are disclosed in copending
applications U.S. Pat. No. 6,268,444, U.S. Pat. No. 6,515,155, U.S.
Ser. Nos. 60/215,456, 60/170,175 and 60/393,862. These catalysts
tend to have the capability of producing higher molecular weight
polymers. Yet other catalysts, cocatalysts, catalyst systems, and
activating techniques which may be used include those disclosed in
WO 96/23010, 99/14250, 98/41529 and 97/42241; Scollard, et al., in
J. Am. Chem. Soc 1996, 118, 10008-10009; EP 0 468 537 B1; WO
97/22635; EP 0 949 278 A2, 0 949 279 A2, and 1 063 244 A2; U.S.
Pat. Nos. 5,408,017, 5,767,208 and 5,907,021; WO 88/05792, 88/05793
and 93/25590; U.S. Pat. Nos. 5,599,761 and 5,218,071; WO 90/07526;
U.S. Pat. Nos. 5,972,822, 6,074,977, 6,013,819, 5,296,433,
4,874,880, 5,198,401, 5,621,127, 5,703,257, 5,728,855, 5,731,253,
5,710,224, 5,883,204, 5,504,049, 5,962,714, 5,965,677 and
5,427,991; WO 93/21238, 94/03506, 93/21242, 94/00500, 96/00244 and
98/50392; Wang, et al., Organometallics 1998, 17, 3149-3151;
Younkin, et al., Science 2000, 287, 460-462; Chen and Marks, Chem.
Rev. 2000, 100, 1391-1434; Alt and Koppl, Chem. Rev. 2000, 100,
1205-1221; Resconi, et al., Chem. Rev. 2000, 100, 1253-1345; Ittel,
et al., ChemRev. 2000, 100, 1169-1203; Coates, Chem. Rev., 2000,
100, 1223-1251; U.S. Pat. Nos. 5,093,415, 6,303,719 and 5,874,505;
and WO 96/13530. Also useful are those catalysts, cocatalysts and
catalyst systems disclosed in U.S. Pat. Nos. 6,268,444, 6,515,155,
5,965,756 and 6,150,297.
Process Descriptions
[0229] The polymers, including the P* and P/E* polymers, used in
the practice of this invention can be made by any convenient
process. In one embodiment, the process reagents, i.e., (i)
propylene, (ii) ethylene and/or one or more unsaturated comonomers,
(iii) catalyst, and, (iv) optionally, solvent and/or a molecular
weight regulator (e.g., hydrogen), are fed to a single reaction
vessel of any suitable design, e.g., stirred tank, loop,
fluidized-bed, etc. The process reagents are contacted within the
reaction vessel under appropriate conditions (e.g., solution,
slurry, gas phase, suspension, high pressure) to form the desired
polymer, and then the output of the reactor is recovered for
post-reaction processing. All of the output from the reactor can be
recovered at one time (as in the case of a single pass or batch
reactor), or it can be recovered in the form of a bleed stream
which forms only a part, typically a minor part, of the reaction
mass (as in the case of a continuous process reactor in which an
output stream is bled from the reactor at the same rate at which
reagents are added to maintain the polymerization at steady-state
conditions). "Reaction mass" means the contents within a reactor,
typically during or subsequent to polymerization. The reaction mass
includes reactants, solvent (if any), catalyst, and products and
by-products. The recovered solvent and unreacted monomers can be
recycled back to the reaction vessel.
[0230] The polymerization conditions at which the reactor is
operated are similar to those for the polymerization of propylene
using a known, conventional Ziegler-Natta catalyst. Typically,
solution polymerization of propylene is performed at a
polymerization temperature between about -50 to about 200,
preferably between about -10 and about 150, C., and more preferably
between about 20 to about 150 C. and most preferably between about
80 and 150 C., and the polymerization pressure is typically between
about atmospheric to about 7, preferably between about 0.2 and
about 5, Mpa. If hydrogen is present, then it is usually present at
a partial pressure (as measured in the gas phase portion of the
polymerization) of about 0.1 kPa to about 5 Mpa, preferably between
about 1 kPa to about 3 Mpa. Gas phase, suspension and other
polymerization schemes will use conditions conventional for those
schemes. For gas-phase or slurry-phase polymerization processes, it
is desirable to perform the polymerization at a temperature below
the melting point of the polymer.
[0231] For the propylene/ethylene copolymer processes described
herein, optionally containing additional unsaturated monomer, the
weight ratio of propylene to ethylene in the feed to the reactors
is preferably in the range of 10,000:1 to 1;10, more preferably
1,000:1 to 1:1, still more preferably 500:1 to 3:1. For the
propylene/C.sub.4-20 .alpha.-olefin copolymer processes, the weight
ratio of propylene to C.sub.4-20 .alpha.-olefin in the feed
preferably is in the range of 10,000:1 to 1:20, more preferably
1,000:1 to 1:1, still more preferably 1,000:1 to 3:1.
[0232] The post-reactor processing of the recover reaction mass
from the polymerization vessel typically includes the deactivation
of the catalyst, removal of catalyst residue, drying of the
product, and the like. The recovered polymer is then ready for
storage and/or use.
[0233] The P* and P/E*polymers produced in a single reaction vessel
will have the desired MFR, narrow MWD, .sup.13C NMR peaks at 14.6
and 15.7 ppm (the peaks of approximately equal intensity), high
B-value (if a P/E* copolymer), and its other defining
characteristics. If, however, a broader MWD is desired, e.g., a MWD
of between about 2.5 and about 3.5 or even higher, without any
substantial change to the other defining characteristics of the
propylene copolymer, then the copolymer is preferably made in a
multiple reactor system. In multiple reactor systems, MWD as broad
as 15, more preferably 10, most preferably 4-8, can be
prepared.
[0234] Preferably, to obtain a broad MWD, at least two of the
catalysts used in a single reactor have a high weight-average
molecular weight (M.sub.wH)/low weight average molecular weight
(M.sub.wL) ratio (M.sub.wH/M.sub.wL, as defined later) in the range
from about 1.5 to about 10, and the process used is a gas phase,
slurry, or solution process. More preferably, at least two of the
catalysts used in a single reactor have M.sub.wH/M.sub.wL in the
range from about 1.5 to about 10, and the process used is a
continuous solution process, especially a continuous solution
process wherein the polymer concentration in the reactor at steady
state is at least 15% by weight of the reactor contents. Still more
preferably, at least two of the catalysts used in a single reactor
have M.sub.wH/M.sub.wL in the range from about 1.5 to about 10, and
the process used is a continuous solution process wherein the
polymer concentration in the reactor at steady state is at least
18% by weight of the reactor contents. Most preferably, at least
two of the catalysts used in a single reactor have
M.sub.wH/M.sub.wL in the range from about 1.5 to about 10, and the
process used is a continuous solution process wherein the polymer
concentration in the reactor at steady state is at least 20% by
weight of the reactor contents.
[0235] In one embodiment, the monomers comprise propylene and at
least one olefin selected from the group consisting of
C.sub.4-C.sub.10 .alpha.-olefins, especially 1-butene, 1-hexene,
and 1-octene, and the melt flow rate (MFR) of the interpolymer is
preferably in the range of about 0.1 to about 500, more preferably
in the range from about 0.1 to about 100, further more preferably
about 0.2 to 80, most preferably in the range of 0.3-50. In some
embodiments, the nonmetallocene, catalysts described herein may be
utilized in combination with at least one additional homogeneous or
heterogeneous polymerization catalyst in separate reactors
connected in series or in parallel to prepare polymer blends having
desirable properties. An example of such a process is disclosed in
WO 94/00500, equivalent to U.S. Ser. No. 07/904,770, as well as
U.S. Ser. No. 08/10958, filed Jan. 29, 1993. Included in these
embodiments is the use of two different nonmetallocene,
metal-centered, heteroaryl ligand catalysts.
[0236] The catalyst system may be prepared as a homogeneous
catalyst by addition of the requisite components to a solvent in
which polymerization will be carried out by solution polymerization
procedures. The catalyst system may also be prepared and employed
as a heterogeneous catalyst by adsorbing the requisite components
on a catalyst support material such as silica gel, alumina or other
suitable inorganic support material. When prepared in heterogeneous
or supported form, it is preferred to use silica as the support
material. The heterogeneous form of the catalyst system may be
employed in a slurry or gas phase polymerization. As a practical
limitation, slurry polymerization takes place in liquid diluents in
which the polymer product is substantially insoluble. Preferably,
the diluent for slurry polymerization is one or more hydrocarbons
with less than 5 carbon atoms. If desired, saturated hydrocarbons
such as ethane, propane or butane may be used in whole or part as
the diluent. Likewise the .alpha.-olefin comonomer or a mixture of
different .alpha.-olefin comonomers may be used in whole or part as
the diluent. Most preferably, the major part of the diluent
comprises at least the .alpha.-olefin monomer or monomers to be
polymerized.
[0237] Solution polymerization conditions utilize a solvent for the
respective components of the reaction. Preferred solvents include,
but are not limited to, mineral oils and the various hydrocarbons
which are liquid at reaction temperatures and pressures.
Illustrative examples of useful solvents include, but are not
limited to, alkanes such as pentane, iso-pentane, hexane, heptane,
octane and nonane, as well as mixtures of alkanes including
kerosene and Isopar E.TM., available from Exxon Chemicals Inc.;
cycloalkanes such as cyclopentane, cyclohexane, and
methylcyclohexane; and aromatics such as benzene, toluene, xylenes,
ethylbenzene and diethylbenzene.
[0238] The polymerization may be carried out as a batch or a
continuous polymerization process. A continuous process is
preferred, in which event catalysts, solvent or diluent (if
employed), and comonomers (or monomer) are continuously supplied to
the reaction zone and polymer product continuously removed
therefrom. The polymerization conditions for manufacturing the
interpolymers are generally those useful in the solution
polymerization process, although the application is not limited
thereto. Gas phase and slurry polymerization processes are also
believed to be useful, provided the proper catalysts and
polymerization conditions are employed.
[0239] The following procedure may be carried out to obtain a P/E*
copolymer. In a stirred-tank reactor propylene monomer is
introduced continuously together with solvent, and ethylene
monomer. The reactor contains a liquid phase composed substantially
of ethylene and propylene monomers together with any solvent or
additional diluent. If desired, a small amount of a "H"-branch
inducing diene such as norbornadiene, 1,7-octadiene or
1,9-decadiene may also be added. A nonmetallocene, metal-centered,
heteroaryl ligand catalyst and suitable cocatalyst are continuously
introduced in the reactor liquid phase. The reactor temperature and
pressure may be controlled by adjusting the solvent/monomer ratio,
the catalyst addition rate, as well as by cooling or heating coils,
jackets or both. The polymerization rate is controlled by the rate
of catalyst addition. The ethylene content of the polymer product
is determined by the ratio of ethylene to propylene in the reactor,
which is controlled by manipulating the respective feed rates of
these components to the reactor. The polymer product molecular
weight is controlled, optionally, by controlling other
polymerization variables such as the temperature, monomer
concentration, or by a stream of hydrogen introduced to the
reactor, as is known in the art. The reactor effluent is contacted
with a catalyst kill agent, such as water. The polymer solution is
optionally heated, and the polymer product is recovered by flashing
off unreacted gaseous ethylene and propylene as well as residual
solvent or diluent at reduced pressure, and, if necessary,
conducting further devolatilization in equipment such as a
devolatilizing extruder or other devolatilizing equipment operated
at reduced pressure. For a solution polymerization process,
especially a continuous solution polymerization, preferred ranges
of propylene concentration at steady state are from about 0.05
weight percent of the total reactor contents to about 50 weight
percent of the total reactor contents, more preferably from about
0.5 weight percent of the total reactor contents to about 30 weight
percent of the total reactor contents, and most preferably from
about 1 weight percent of the total reactor contents to about 25
weight percent of the total reactor contents. The preferred range
of polymer concentration (otherwise known as % solids) is from
about 3% of the reactor contents by weight to about 45% of the
reactor contents or higher, more preferably from about 10% of the
reactor contents to about 40% of the reactor contents, and most
preferably from about 15% of the reactor contents to about 40% of
the reactor contents.
[0240] In a continuous process, the mean residence time of the
catalyst and polymer in the reactor generally is from 5 minutes to
8 hours, and preferably from 10 minutes to 6 hours, more preferably
from 10 minutes to 1 hour.
[0241] In some embodiments, ethylene is added to the reaction
vessel in an amount to maintain a differential pressure in excess
of the combined vapor pressure of the propylene and diene monomers.
The ethylene content of the polymer is determined by the ratio of
ethylene differential pressure to the total reactor pressure.
Generally the polymerization process is carried out with a pressure
of ethylene of from 10 to 1000 psi (70 to 7000 kPa), most
preferably from 40 to 800 psi (30 to 600 kPa). The polymerization
is generally conducted at a temperature of from 25 to 250.degree.
C., preferably from 75 to 200.degree. C., and most preferably from
greater than 95 to 200.degree. C.
[0242] In another embodiment, a process for producing a propylene
homopolymer or interpolymer of propylene with at least one
additional olefinic monomer selected from ethylene or C.sub.4-20
.alpha.-olefins comprises the following steps: 1) providing
controlled addition of a nonmetallocene, metal-centered, heteroaryl
ligand catalyst to a reactor, including a cocatalyst and optionally
a scavenger component; 2) continuously feeding propylene and
optionally one or more additional olefinic monomers independently
selected from ethylene or C.sub.4-20 .alpha.-olefins into the
reactor, optionally with a solvent or diluent, and optionally with
a controlled amount of H.sub.2; and 3) recovering the polymer
product. Preferably, the process is a continuous solution process.
The cocatalysts and optional scavenger components in the novel
process can be independently mixed with the catalyst component
before introduction into the reactor, or they may each
independently be fed into the reactor using separate streams,
resulting in "in reactor" activation. Scavenger components are
known in the art and include, but are not limited to, alkyl
aluminum compounds, including alumoxanes. Examples of scavengers
include, but are not limited to, trimethyl aluminum, triethyl
aluminum, triisobutyl aluminum, trioctyl aluminum, methylalumoxane
(MAO), and other alumoxanes including, but not limited to, MMAO-3A,
MMAO-7, PMAO-IP (all available from Akzo Nobel).
[0243] As previously noted, the process described above may
optionally use more than one reactor. The use of a second reactor
is especially useful in those embodiments in which an additional
catalyst, especially a Ziegler-Natta or chrome catalyst, or a
metallocene catalyst, especially a CGC, is employed. The second
reactor typically holds the additional catalyst.
[0244] By proper selection of process conditions, including
catalyst selection, polymers with tailored properties can be
produced. For a solution polymerization process, especially a
continuous solution polymerization, preferred ranges of ethylene
concentration at steady state are from less than about 0.02 weight
percent of the total reactor contents to about 5 weight percent of
the total reactor contents, and the preferred range of polymer
concentration is from about 10% of the reactor contents by weight
to about 45% of the reactor contents or higher.
[0245] In general, catalyst efficiency (expressed in terms of gram
of polymer produced per gram of transition metal) decreases with
increasing temperature and decreasing ethylene concentration. In
addition, the molecular weight of the polymer product generally
decreases with increasing reactor temperature and decreases with
decreasing propylene and ethylene concentration. The molecular
weight of the polyolefin can also be controlled with the addition
of chain transfer compounds, especially through the addition of
H.sub.2.
[0246] The gas phase processes are continuous processes which
provide for the continuous supply of reactants to the reaction zone
of the reactor and the removal of products from the reaction zone
of the reactor, thereby providing a steady-state environment on the
macro scale in the reaction zone of the reactor. Products are
readily recovered by exposure to reduced pressure and optionally
elevated temperatures (devolatilization) according to known
techniques. Typically, the fluidized bed of the gas phase process
is operated at temperatures greater than 50.degree. C., preferably
from about 60.degree. C. to about 110.degree. C., more preferably
from about 70.degree. C. to about 110.degree. C.
[0247] A number of patents and patent applications describe gas
phase processes, particularly, U.S. Pat. Nos. 4,588,790; 4,543,399;
5,352,749; 5,436,304; 5,405,922; 5,462,999; 5,461,123; 5,453,471;
5,032,562; 5,028,670; 5,473,028; 5,106,804; 5,556,238; 5,541,270;
5,608,019; 5,616,661; and EP applications 659,773; 692,500;
780,404; 697,420; 628,343; 593,083; 676,421; 683,176; 699,212;
699,213; 721,798; 728,150; 728,151; 728,771; 728,772; 735,058; and
PCT Applications WO-94/29032, WO-94/25497, WO-94/25495,
WO-94/28032, WO-95/13305, WO-94/26793, WO-95/07942, WO-97/25355,
WO-93/11171, WO-95/13305, and WO-95/13306.
Applications
[0248] The polymers made in accordance with embodiments of the
invention have many useful applications. For example, fabricated
articles made from the polymers may be prepared using all of the
conventional polyolefin processing techniques. Useful film articles
include cast, blown, calendered and extrusion coated (including
multi-layer films, greenhouse films, shrink films including clarity
shrink film, lamination film, biaxially-oriented film, extrusion
coating, liners, clarity liners, overwrap film and agricultural
film). Monolayer and multilayer films may be made according to the
film structures and fabrication methods described in U.S. Pat. No.
5,685,128.
[0249] The films made in accordance with this invention have many
utilities, including over-wrapping films such as tissue over-wraps,
bundled bottled water over-wraps; clarity films such as candy bags,
bread bags, envelope window films; food and specialty packaging
films, such as produce bags, meat wraps, cheese wraps, etc.;
pouches such as milk pouch, bags-in-box such as wine and other
verical form fill and seal techniques such as those taught by Dow,
DuPont and Exxon. Shrinkage films are also within the purview of
the invention, and these can be made using a variety of techniques,
such as double bubble films, tenter frame techniques, biaxial
orientation techniques (such as that taught by Pahlke). The films
of the invention can also be elastic.
[0250] With respect to blown film applications, the films
comprising P* and/or P/E* polymers exhibit excellent optics, e.g.,
low haze and high gloss, and much better toughness (e.g., tear and
dart) than traditional Ziegler-Natta catalyzed polypropylene at
comparable ethylene contents. These characteristics are shown in
the Figures and examples. Moreover, blown films made from P* and/or
P/E* polymers exhibit excellent hot tack and heat seal properties
(e.g., a broader temperature window for the former and a lower
sealing temperature for the latter than comparable Ziegler-Natta
catalyzed polypropylene, even when the latter has a higher ethylene
content).
[0251] The P* and P/E* polymers are also useful for wire and cable
coating operations, wire and cable jacketing, including low, medium
and high voltage cable jacketing, semi-conductive layers used in
wire and cable power applications, wire and cable insulation,
especially medium and high voltage cable insulation,
telecommunications cable jackets, optical fiber jackets, as well as
in sheet extrusion for vacuum forming operations. In addition, the
P* and P/E* polymers may be used in foams, including high strength
foam, soft foam, rigid foam, cross-linked foam, high strength foam
for cushioning applications, and sound insulation foam, blow molded
bottles, frozen food packages; thermoforming, especially cups and
plates, trays and containers; injection moulding; blow-moulding;
pipe, including potable water pipe and high pressure pipe; and
automotive parts. The skilled artisan will appreciate other uses
for the novel polymers and compositions disclosed herein.
[0252] Useful compositions are also suitably prepared comprising
the P* and/or P/E* polymers according to embodiments of the
invention and at least one other natural or synthetic polymer.
Preferred other polymers include, but are not limited to,
thermoplastics, such as styrene-butadiene block copolymers,
polystyrene (including high impact polystyrene), ethylene vinyl
alcohol copolymers, ethylene acrylic acid copolymers, other olefin
copolymers (especially polyethylene copolymers) and homopolymers
(e.g., those made using conventional heterogeneous catalysts).
Examples include polymers made by the process of U.S. Pat. No.
4,076,698, other linear or substantially linear polymers as
described in U.S. Pat. No. 5,272,236, and mixtures thereof. Other
substantially linear polymers and conventional HDPE and/or LDPE may
also be used in the thermoplastic compositions.
[0253] In one aspect of the present invention, the P* and P/E*
polymers are useful for a wide range of applications where good
optical properties are beneficial. Gloss is measured according to
ASTM D-1746. Haze is measured according to ASTM D-1003, and Clarity
is measured according to ASTM D-2457. With the P* and P/E*
polymers, films having haze of less than 10% can be produced. In
addition, these polymers can also produce films having clarity of
greater than 91%.
[0254] The P* and P/E* polymers, either alone or in combination
with one or more other polymers (e.g., a polymer other than a P*
and P/E* polymer) may be blended, if desired or necessary, with
various additives such as antioxidants, ultraviolet absorbing
agents, antistatic agents, nucleating agents, lubricants, flame
retardants, antiblocking agents, colorants, inorganic or organic
fillers or the like.
[0255] The P* and P/E* polymers can be blended with other polymers
to form a film layer of the invention. Suitable polymers for
blending with the P* and P/E* polymers are commercially available
from a variety of suppliers and include, but are not limited to,
other polyolefins such as an ethylene polymer (e.g., low density
polyethylene (LDPE), ULDPE, medium density polyethylene (MDPE),
LLDPE, HDPE, homogeneously branched linear ethylene polymer,
substantially linear ethylene polymer, graft-modified ethylene
polymer ethylene-styrene interpolymers, ethylene vinyl acetate
interpolymer, ethylene acrylic acid interpolymer, ethylene ethyl
acetate interpolymer, ethylene methacrylic acid interpolymer,
ethylene methacrylic acid ionomer, and the like), polycarbonate,
polystyrene, conventional polypropylene (e.g., homopolymer
polypropylene, polypropylene copolymer, random block polypropylene
interpolymer and the like), thermoplastic polyurethane, polyamide,
polylactic acid interpolymer, thermoplastic block polymer (e.g.
styrene butadiene copolymer, styrene butadiene styrene triblock
copolymer, styrene ethylene-butylene styrene triblock copolymer and
the like), polyether block copolymer (e.g., PEBAX), copolyester
polymer, polyester/polyether block polymers (e.g., HYTEL), ethylene
carbon monoxide interpolymer (e.g., ethylene/carbon monoxide (ECO),
copolymer, ethylene/acrylic acid/carbon monoxide (EAACO)
terpolymer, ethylene/methacrylic acid/carbon monoxide (EMAACO)
terpolymer, ethylene/vinyl acetate/carbon monoxide (EVACO)
terpolymer and styrene/carbon monoxide (SCO)), polyethylene
terephthalate (PET), chlorinated polyethylene, and the like and
mixtures thereof. In other words, the polyolefin used in the
practice of this invention can be a blend of two or more
polyolefins, or a blend of one or more polyolefins with one or more
polymers other than a polyolefin. If the polyolefin used in the
practice of this invention is a blend of one or more polyolefins
with one or more polymers other than a polyolefin, then the
polyolefins comprise at least about 1, preferably at least about 50
and more preferably at least about 90, wt % of the total weight of
the blend.
[0256] In one embodiment, one or more P* and P/E* polymers is
blended with a conventional polypropylene polymer. Suitable
conventional polypropylene polymers for use in the invention,
including random propylene ethylene polymers, are available from a
number of manufacturers, such as, for example, Montell Polyolefins
and Exxon Chemical Company. Suitable conventional polypropylene
polymers from Exxon are supplied under the designations ESCORENE
and ACHIEVE.
[0257] Suitable graft-modified polymers for use in this invention
are well known in the art, and include the various ethylene
polymers bearing a maleic anhydride and/or another
carbonyl-containing, ethylenically unsaturated organic radical.
Representative graft-modified polymers are described in U.S. Pat.
No. 5,883,188, such as a homogeneously branched ethylene polymer
graft-modified with maleic anhydride.
[0258] Suitable polylactic acid (PLA) polymers for use in the
invention are well known in the literature (e.g., see D. M. Bigg et
al., "Effect of Copolymer Ratio on the Crystallinity and Properties
of Polylactic Acid Copolymers", ANTEC '96, pp. 2028-2039; WO
90/01521; EP 0 515 203A and EP 0 748 846 A2. Suitable polylactic
acid polymers are supplied commercially by Cargill Dow under the
designation EcoPLA.
[0259] Suitable thermoplastic polyurethane polymers for use in the
invention are commercially available from The Dow Chemical Company
under the designation PELLETHANE.
[0260] Suitable polyolefin carbon monoxide interpolymers can be
manufactured using well known high pressure free-radical
polymerization methods. However, they may also be manufactured with
the use of so-called homogeneous catalyst systems such as those
described and referenced above.
[0261] Suitable free-radical initiated high pressure
carbonyl-containing ethylene polymers such as ethylene acrylic acid
interpolymers can be manufactured by any technique known in the art
including the methods taught by Thomson and Waples in U.S. Pat.
Nos. 3,520,861, 4,988,781; 4,599,392 and 5,384,373.
[0262] Suitable ethylene vinyl acetate interpolymers for use in the
invention are commercially available from various suppliers,
including Exxon Chemical Company and Du Pont Chemical Company.
[0263] Suitable ethylene/alkyl acrylate interpolymers are
commercially available from various suppliers. Suitable
ethylene/acrylic acid interpolymers are commercially available from
The Dow Chemical Company under the designation PRIMACOR. Suitable
ethylene/methacrylic acid interpolymers are commercially available
from Du Pont Chemical Company under the designation NUCREL.
[0264] Chlorinated polyethylene (CPE), especially chlorinated
substantially linear ethylene polymers, can be prepared by
chlorinating polyethylene in accordance with well known techniques.
Preferably, chlorinated polyethylene comprises equal to or greater
than 30 weight percent chlorine. Suitable chlorinated polyethylenes
for use in the invention are commercially supplied by The Dow
Chemical Company under the designation TYRIN.
[0265] The P* and P/E* polymers, if elastic, can also be shaped or
fabricated into elastic-films, coatings, sheets, strips, tapes,
ribbons and the like. The elastic film, coating and sheet of the
present invention may be fabricated by any method known in the art,
including blown bubble processes (e.g., simple bubble as well as
biaxial orientation techniques such trapped bubble, double bubble
and tenter framing), cast extrusion, injection molding processes,
thermoforming processes, extrusion coating processes, profile
extrusion, and sheet extrusion processes. Simple blown bubble film
processes are described, for example, in The Encyclopedia of
Chemical Technology, Kirk-Othmer, Third Edition, John Wiley &
Sons, New York, 1981, Vol. 16, pp. 416-417 and Vol. 18, pp.
191-192. The cast extrusion method is described, for example, in
Modem Plastics Mid-October 1989 Encyclopedia Issue, Volume 66,
Number 11, pages 256 to 257. Injection molding, thermoforming,
extrusion coating, profile extrusion, and sheet extrusion processes
are described, for example, in Plastics Materials and Processes,
Seymour S. Schwartz and Sidney H. Goodman, Van Nostrand Reinhold
Company, New York, 1982, pp. 527-563, pp. 632-647, and pp.
596-602.
[0266] Not only can the P* and P/E* polymers be blended with one or
more other polymers, but they can also be blended with various
additives such as nucleating, clarifying, stiffness and/or
crystallization rate agents. These agents are used in a
conventional matter and in conventional amounts.
[0267] The P* and P/E* polymers can also be functionalized by
adding one or more functional groups, e.g. through the use of a
functionalized azide, to the polymer chain in a post-reaction
operation. Optionally, the P* and P/E* polymers can be subjected to
post-reaction treatments, e.g. crosslinking, vis-breaking, and the
like. Vis-breaking is particularly useful in reducing the viscosity
of high molecular weight polymers. These post treatments are also
used in their conventional manner.
[0268] The following examples are given to illustrate various
embodiments of the invention. They do not intend to limit the
invention as otherwise described and claimed herein. All numerical
values are approximate. When a numerical range is given, it should
be understood that embodiments outside the range are still within
the scope of the invention unless otherwise indicated. In the
following examples, various polymers were characterized by a number
of methods. Performance data of these polymers were also obtained.
Most of the methods or tests were performed in accordance with an
ASTM standard, if applicable, or known procedures. All parts and
percentages are by weight unless otherwise indicated FIGS. 12A-J
illustrate the chemical structures of various catalysts described
in the following examples.
Specific Embodiments
[0269] Tetrahydrofuran (THF), diethyl ether, toluene, hexane, and
ISOPAR E (obtainable from Exxon Chemicals) are used following
purging with pure, dry nitrogen and passage through double columns
charged with activated alumina and alumina supported mixed metal
oxide catalyst (Q-5 catalyst, available from Engelhard Corp). All
syntheses and handling of catalyst components are performed using
rigorously dried and deoxygenated solvents under inert atmospheres
of nitrogen or argon, using either glove box, high vacuum, or
Schlenk techniques, unless otherwise noted. MMAO-3A, PMAO, and
PMAO-IP can be purchased from Akzo-Nobel Corporation.
Synthesis of
(C.sub.5Me.sub.4SiMe.sub.2N.sup.tBu)Ti(.eta..sup.4-1,3-pentadiene)
(Catalyst A)
[0270] Catalyst A can be synthesized according to Example 17 of
U.S. Pat. No. 5,556,928.
Synthesis of dimethylsilyl(2-methyl-s-indacenyl)(t-butylamido)
titanium 1,3-pentadiene (Catalyst B)
[0271] Catalyst B can be synthesized according to Example 23 of
U.S. Pat. No. 5,965,756.
Synthesis of
(N-(1,1-dimethylethyl)-1,1-di-p-tolyl-1-((1,2,3,3a,7a-.eta.)-3-(1,3-dihyd-
ro-2H-isoindol-2-yl)-1H-inden-1-yl)silanaminato-(2-)-N-)dimethyltitanium
(Catalyst C)
[0272] (1) Preparation of
dichloro(N-(1,1-dimethylethyl)-1,1-di(p-tolyl)-1-((1,2,3,3a,7a-.eta.)-3-(-
1,3-dihydro-2H-isoindol-2-yl)-1H-inden-1-yl)silanaminato-(2-)-N-)-titanium
##STR24##
[0273] (A) Preparation of
N-(tert-butyl)-N-(1,1-p-tolyl)-1-(3-(1,3-dihydro-2H-isoindol-2-yl)-1H-ind-
enyl)silyl)amine: ##STR25##
[0274] To a 1.70 g (5.35 mmol) of
N-(tert-butyl)-N-(1-chloro-1,1-di(3-p-tolyl)silylamine dissolved in
20 mL of THF is added 1.279 g (5.35 mmol) of
1-(1H-3-indenyl)-1-(2,3-dihydro-1H-isoindolinyl) lithium salt
dissolved in 20 mL of THF. After the addition, the reaction mixture
is stirred for 9 hours and then solvent is removed under reduced
pressure. The residue is extracted with 40 mL of hexane and
filtered. Solvent is removed under reduced pressure giving 2.806 of
product as a gray solid.
[0275] .sup.1H (C.sub.6D.sub.6) .delta.: 1.10 (s, 9H), 2.01 (s,
3H), 2.08 (s, 3H), 4.12 (d, 1H, .sup.3J.sub.H-H=1.5 Hz), 4.39 (d,
1H, .sup.2J.sub.H-H=11.1 Hz), 4.57 (d, 1H, .sup.2J.sub.H-H=11.7
Hz), 5.55 (d, 1H, .sup.3J.sub.H-H=2.1 Hz), 6.9-7.22 (m, 10H), 7.56
(d, 1H, .sup.3J.sub.H-H=7.8 Hz), 7.62 (d, 1H, .sup.3J.sub.H-H=6.9
Hz), 7.67 (d, 1H, .sup.3J.sub.H-H=7.8 Hz), 7.83 (d, 1H,
.sup.3J.sub.H-H=7.8 Hz).
[0276] .sup.13C{.sup.1H} (C.sub.6D.sub.6) .delta.: 21.37, 21.43,
33.78, 41.09, 50.05, 56.56, 104.28, 120.98, 122.46, 123.84, 124.71,
124.84, 126.98, 128.29, 128.52, 129.05, 132.99, 133.68, 135.08,
135.90, 136.01, 138.89, 139.05, 139.09, 141.27, 146.39, 148.48.
[0277] (B) Preparation of
N-(tert-butyl)-N-(1,1-p-tolyl)-1-(1,3-dihydro-2H-isoindol-2-yl)-1H-indeny-
l)silyl)amine, Dilithium Salt:
[0278] To a 50 mL hexane solution containing 2.726 g (5.61 mmol) of
the
N-(tert-butyl)-N-(1,1-p-tolyl)-1-(3-(1,3-dihydro-2H-isoindol-2-yl)-1H-ind-
enyl)silyl)amine is added 7.4 mL of 1.6 M n-BuLi solution. During
addition of the n-BuLi, a yellow precipitate appears. After
stirring for 6 hours, the yellow precipitate is collected on a
frit, washed with 2.times.25 mL of hexane, and dried under reduced
pressure to give 2.262 g of the product as a yellow powder.
[0279] .sup.1H (C.sub.6D.sub.6) .delta.: 1.17 (s, 9H), 2.30 (s,
6H), 4.51 (s, 4H), 6.21 (s, 1H), 6.47 (m, 2H), 6.97 (d, 4H,
.sup.3J.sub.H-H=8.1 Hz), 7.15 (m, 2H), 7.23 (m, 2H), 7.50 (m, 1H),
7.81 (d, 4H, .sup.3J.sub.H-H=7.8 Hz), 8.07 (d, 1H,
.sup.3J.sub.H-H=7.2 Hz). .sup.13C{.sup.1H} (C.sub.6D.sub.6)
.delta.: 21.65, 38.83, 52.46, 59.82, 95.33, 112.93, 114.15, 115.78,
118.29, 122.05, 122.60, 124.16, 124.78, 126.94, 127.30, 133.06,
134.75, 137.30, 141.98, 148.17.
[0280] (C) Preparation of
dichloro(N-(1,1-dimethylethyl)-1,1-di-p-tolyl-1-((1,2,3,3a,7a-.eta.)-3-(1-
,3-dihydro-2H-isoindol-2-yl)-1H-inden-1-yl)silanaminato-(2-)-N-)titanium:
[0281] In the drybox 1.552 g (4.19 mmol) of TiCl.sub.3(THF) 3 is
suspended in 20 mL of THF. To this solution, 2.206 g (4.19 mmol) of
N-(tert-butyl)-N-(1,1-p-tolyl)-1-(1,3-dihydro-2H-isoindol-2-yl)-1H-indeny-
l)silyl)amine, dilithium salt dissolved in 30 mL of THF is added
within 1 minute. The solution is then stirred for 60 minutes. After
this time, 0.76 g of PbCl.sub.2 (2.75 mmol) is added and the
solution is stirred for 60 minutes. The THF is then removed under
reduced pressure. The residue is first extracted with 60 mL of
methylene chloride and filtered. Solvent is removed under reduced
pressure leaving a black crystalline solid. Hexane is added (30 mL)
and the black suspension is stirred for 10 hour. The solids are
collected on a frit, washed with 30 mL of hexane and dried under
reduced pressure to give 2.23 g of the desired product as a deep
purple solid.
[0282] .sup.1H (THF-d.sub.8) .delta.: 1.40 (s, 9H) 2.46 (s, 3H),
2.48 (s, 3H), 5.07 (d, 2H, .sup.2J.sub.H-H=12.3 Hz), 5.45 (d, 2H,
.sup.2J.sub.H-H=12.6 Hz), 5.93 (s, 1H), 6.95 (d, 1H,
.sup.3J.sub.H-H=9.0 Hz), 7.08 (d, 1H, .sup.3J.sub.H-H=7.8 Hz),
7.15-7.4 (m, 9H), 7.76 (d, 1H, .sup.3J.sub.H-H=7.8 Hz), 7.82 (d,
1H, .sup.3J.sub.H-H=7.5 Hz), 8.05 (d, 1H, .sup.3J.sub.H-H=8.7 Hz).
.sup.13C{.sup.1H} (THF-d.sub.8) .delta.: 21.71, 21.76, 33.38,
56.87, 61.41, 94.5, 107.95, 122.86, 125.77, 126.68, 127.84, 127.92,
128.40, 128.49, 129.36, 129.79, 131.23, 131.29, 135.79, 136.43,
136.73, 141.02, 141.22, 150.14.
[0283] (2) Preparation of
(N-(1,1-dimethylethyl)-1,1-di-p-tolyl-1-((1,2,3,3a,7a-.eta.)-3-(1,3-dihyd-
ro-2H-isoindol-2-yl)-1H-inden-1-yl)silanaminato-(2-)-N-)dimethyltitanium:
##STR26##
[0284] In the drybox 0.50 g of
dichloro(N-(1,1-dimethylethyl)-1,1-di-p-tolyl-1-((1,2,3,3a,7a-.eta.)-3-(1-
,3-dihydro-2H-isoindol-2-yl)-1H-inden-1-yl)silanaminato-(2-)-N-)titanium
complex (0.79 mmol) is dissolved in 30 mL of diethyl ether. To this
solution, 1.14 mL (1.6 mmol) of MeLi (1.6 M in ether) is added
dropwise while stirring over a 1 minute period. After the addition
of MeLi is completed, the solution is stirred for 1.5 hour. Diethyl
ether is removed under reduced pressure and the residue extracted
with 45 mL of hexane. Hexane is removed under reduced pressure
giving a red crystalline material. This solid is dissolved in about
7 mL of toluene and 25 mL of hexane, filtered, and the solution was
put into the freezer (-27.degree. C.) for 2 days. The solvent is
then decanted and the resulting crystals are washed with cold
hexane and dried under reduced pressure to give 156 mg of
product.
[0285] .sup.1H (C.sub.6D.sub.6) .delta.: 0.25 (s, 3H), 0.99 (3H),
1.72 (s, 9H), 2.12 (s, 3H), 2.15 (s, 3H), 4.53 (d, 2H,
.sup.2J.sub.H-H=11.7 Hz), 4.83 (d, 2H, .sup.2J.sub.H-H=11.7 Hz),
5.68 (s, 1H), 6.72 (dd, 1H, .sup.3J.sub.H-H=8.6 Hz,
.sup.3J.sub.H-H=6.6 Hz), 6.9-7.2 (m, 11H), 7.30 (d, 1H,
.sup.3J.sub.H-H=8.6 Hz) 7.71 (d, 1H, .sup.3J.sub.H-H=8.5 Hz), 7.93
(d, 1H, .sup.3J.sub.H-H=7.8 Hz), 8.11 (d, 1H, .sup.3J.sub.H-H=7.8
Hz). .sup.13C{.sup.1H} (C.sub.6D.sub.6) .delta.: 21.45, 21.52,
35.30, 50.83, 56.03, 56.66, 57.65, 83.80, 105.64, 122.69, 124.51,
124.56, 125.06, 125.35, 127.33, 128.98, 129.06, 129.22, 133.51,
134.02, 134.62, 136.49, 136.84, 137.69, 139.72, 139.87, 143.84.
Synthesis of (1H-cyclopenta
[1]phenanthrene-2-yl)dimethyl(t-butylamido)silane Titanium Dimethyl
(Catalyst D)
[0286] Catalyst D can be synthesized according to Example 2 of U.S.
Pat. No. 6,150,297.
Synthesis of
rac-[dimethylsilylbis(1-(2-methyl-4-phenyl)indenyl)]zirconium
(1,4-diphenyl-1,3-butadiene) (Catalyst E)
[0287] Catalyst E can be synthesized according to Example 15 of
U.S. Pat. No. 5,616,664.
Synthesis of rac-[1,2-ethanediylbis(1-indenyl)]zirconium
(1,4-diphenyl-1,3-butadiene) (Catalyst F)
[0288] Catalyst F can be synthesized according to Example 11 of
U.S. Pat. No. 5,616,664.
Synthesis of Catalyst G
[0289] Hafnium Tetrakisdimethylamine.
[0290] The reaction is prepared inside of a dry box. A 500 mL round
bottom flask containing a stir bar, is charged with 200 mL of
toluene and LiNMe.sub.2 (21 g, 95%, 0.39 mol). HfCl.sub.4 (29.9 g,
0.093 mol) is added slowly over 2 h. The temperature reaches
55.degree. C. The mixture is stirred overnight at ambient
temperature. The LiCl is filtered off. The toluene is carefully
distilled away from the product. Final purification is achieved by
distillation with a vacuum transfer line attached to a cold
(-78.degree. C.) receiving flask. This process is performed outside
the dry box on a Schlenk line. The material is distilled over at
110-120.degree. C. at 300-600 microns. The 19.2 g of the white
solid is collected.
[0291] 2-formyl-6-naphthylpyridine.
[0292] Inside of a dry box, naphthylboronic acid (9.12 g, 53.0
mmol) and Na.sub.2CO.sub.3 (11.64 g, 110 mmol) are dissolved in 290
mL of degassed 4:1 H.sub.2O/MeOH. This solution is added to a
solution of 8 g (43 mmol) of 2-bromo-6-formylpyridine and 810 mg
(0.7 mmol) of Pd(PPh.sub.3).sub.4 in 290 mL of degassed toluene.
The charged reactor is removed from the dry box, while under a
blanket of N.sub.2 and is connected to the house N.sub.2 line. The
biphasic solution is vigorously stirred and heated to 70.degree. C.
for 4 h. On cooling to RT, the organic phase is separated. The
aqueous layer is washed with 3.times.75 mL of Et.sub.2O. The
combined organic extracts are washed with 3.times.100 mL of
H.sub.2O and 1.times.100 mL of brine and dried over
Na.sub.2SO.sub.4. After removing the volatiles in vacuo, the
resultant light yellow oil is purified via trituration with
hexanes. The isolated material is recrystallized from a hot hexane
solution and ultimately yielded 8.75 g, 87% yield. mp 65-66.degree.
C.
[0293] .sup.1H NMR (CDCl.sub.3) .delta. 7.2-8.3 (m, 10H), 10.25 (s,
1 H) ppm. .sup.13C NMR (CDCl.sub.3) 120.3, 125.64, 125.8, 126.6,
127.26, 128.23, 129.00, 129.74, 130.00, 131.39, 134.42, 137.67,
137.97, 153.07, 160.33, 194.23 ppm.
[0294] 6-naphthylpyridine-2-(2,6-diisopropylphenyl)imine:
[0295] A dry, 500 mL 3-neck round bottom flask is charged with a
solution of 5.57 g (23.9 mmol) of 2-formyl-6-naphthlypyridine and
4.81 g (27.1 mmol) of 2,6-diisopropylaniline in 238 mL of anhydrous
THF containing 3 .ANG. molecular sieves (6 g) and 80 mg of p-TsOH.
The loading of the reactor is performed under N.sub.2. The reactor
is equipped with a condenser, an over head mechanical stirrer and a
thermocouple well. The mixture is heated to reflux under N.sub.2
for 12 h. After filtration and removal of the volatile in vacuo,
the crude, brown oil is triturated with hexanes. The product is
filtered off and rinsed with cold hexanes. The slightly off white
solid weighs 6.42 g. No further purification is performed. mp
142-144.degree. C.
[0296] .sup.1H NMR (CDCl.sub.3) .delta. 1.3 (d, 12 H), 3.14 (m,
2H), 7.26 (m, 3H), 7.5-7.6 (m, 5H), 7.75-7.8 (m, 3H), 8.02 (m 1H),
8.48 (m, 2H) ppm. .sup.13C NMR (CDCl.sub.3) 23.96, 28.5, 119.93,
123.50, 124.93, 125.88, 125.94, 126.49, 127.04, 127.24, 128.18,
128.94, 129.7, 131.58, 134.5, 137.56, 137.63, 138.34, 148.93,
154.83, 159.66, 163.86 ppm.
[0297]
(6-naphthyl-2-pyridyl)-N-(2,6-diisopropylphenyl)benzylamine:
[0298] A 250 mL 3-neck flask, equipped with mechanical stirrer and
a N.sub.2 sparge, is charged with
6-naphthylpyridine-2-(2,6-diisopropylphenyl)imine (6.19 mg, 15.8
mmol) and 80 mL of anhydrous, degassed Et.sub.2O. The solution is
cooled to -78.degree. C. while a solution of phenyllithium (13.15
mL of 1.8 M in cyclohexane, 23.7 mmol) is added dropwise over 10
min. After warming to RT over 1 h. the solution is stirred at RT
for 12 hours. The reaction is then quenched with .about.50 mL of
aq. NH.sub.4Cl. The organic layer is separated, washed with brine
and H.sub.2O, then dried over Na.sub.2SO.sub.4. Using the Biotage
Chromatography system (column # FK0-1107-19073, 5% THF/95%
hexanes), the product is isolated as a colorless oil. The
chromatography is performed by dissolving the crude oil in 50 mL of
hexanes. The purification is performed in 2.times..about.25 mL
batches, using half of the hexane stock solution for each run. 7.0
g of the oil is isolated (93% yield).
[0299] .sup.1H NMR (CDCl.sub.3) .delta. 0.90 (d, 12 H), 3.0 (m,
2H), 4.86 (s, 1H), 5.16 (s, 1H), 7.00 (m, 3H), 7.1-7.6 (m, 12H),
7.8-7.88 (m, 2H), 7.91-7.99 (d, 1H) ppm. .sup.13C NMR (CDCl.sub.3)
24.58, 28.30, 70.02, 121.14, 123.62, 123.76, 123.95, 125.71,
126.32, 126.55, 126.74, 127.45, 128.04, 128.74, 129.47, 131.66,
134.49, 137.4, 138.95, 142.68, 143.02, 143.89, 159.36, 162.22
ppm.
[0300] Catalyst G--(Nme.sub.2).sub.3:
[0301] The reaction is performed inside of a dry box. A 100 mL
round bottom flask is charged with Hf(Nme.sub.2).sub.4 (2.5 g, 5.33
mmol), 30 mL of pentane and a stir bar. The amine 1 is dissolve in
40 mL of pentane then added to the stirring solution of
Hf(Nme.sub.2).sub.4. The mixture is stirred at ambient temperature
for 16 h (overnight). The light yellow solid is filtered off and
rinsed with cold pentane. The dry weight of the powder is 2.45 g. A
second crop is collected from the filtrate weighing 0.63 g. The
overall yield is 74%.
[0302] .sup.1H NMR (C.sub.6D.sub.6) .delta. 0.39 (d, 3 H, J=6.77
Hz), 1.36 (d, 3H, J=6.9 Hz), 1.65 (d, 3H, J=6.68 Hz), 1.76 (d, 3H,
J=6.78 Hz ), 2.34 (br s, 6H), 2.80 (br s, 6H), 2.95 (br s, 6H),
3.42 (m, 1H, J=6.8 Hz), 3.78 (m, 1H, J=6.78 Hz), 6.06 (s, 1H), 6.78
(m, 2H), 6.94 (m, 1H), 7.1-7.4 (m, 13H), 7.8 (m, 2H) ppm.
[0303] Catalyst G:
[0304] The reaction is performed inside of a dry box. A 100 mL
round bottom flask is charged with 70 mL of pentane and 15 mL of a
2.0 M trimethyl aluminum in hexane solution. The solution is cooled
to -40.degree. C. The hafnium trisamide compound from the previous
reaction (1.07 g 1.28 mmol) is added in small portions over 5-10
minutes. Upon the addition, a white gelatinous residue forms. After
45-60 min the reaction becomes yellow with a fine, yellow, powder
precipitating from the mixture. After a total reaction time of 2.5
h the mixture is filtered and 615 mg of Catalyst G is isolated as a
bright, yellow powder. No further purification is performed.
[0305] .sup.1H NMR (C.sub.6D.sub.6) .delta. 0.51 (d, 3 H, J=6.73
Hz), 0.79 (s, 3H), 1.07 (s, 3H), 1.28 (d, 3H, J=6.73 Hz), 1.53(m,
6H), 3.37 (m, 1H, J=6.75 Hz), 3.96 (m, 1H, J=6.73 Hz), 6.05 (s,
1H), 6.50 (d, 1H, J=7.75 Hz), 6.92 (t, 1H, J=7.93 Hz), 7.1-7.59 (m,
12H), 7.6 (d, 1H), 7.8-8.0 (m, 2H), 8.3 (m, 1H), 8.69 (d, 1H,
J=7.65 Hz) ppm.
[0306] Synthesis of Catalyst H
[0307] To a solution of 9-bromophenanthrene (10.36 mg, 41 mmol) in
132 mL of anhydrous, degassed Et.sub.2O cooled to -40.degree. C. is
added under N.sub.2 27 mL (43.2 mmol) of a 1.6 M solution of n-BuLi
in hexanes. The solution is swirled to mix and allowed to react at
-40.degree. C. for 3 hours during which colorless crystals
precipitated from solution. The 9-phenanthrenyllithium is added as
a slurry to a well-mixed solution of
6-naphthylpyridine-2-(2,6-diisopropylphenyl)imine (10.6 g, 27.04
mmol) in 130 mL of Et.sub.2O cooled to -40.degree. C. After warming
to ambient temperature over 1 h, the solution is stirred at ambient
temperature for 2 hours. The reaction is then quenched with aq.
NH.sub.4Cl, and subjected to an aqueous/organic work-up. The
organic washes are combined and dried over Na.sub.2SO.sub.4. Upon
removal of the volatiles with rotary evaporation, the product
precipitates from solution. The isolated solids are rinsed with
cold hexanes. The material is vacuum dried at 70.degree. C. using
the house vacuum over night. The dried material is isolated as a
white solid, weighing 12.3 g for a yield of 80%. A second crop is
isolated weighing 0.37 g. Mp 166-168.degree. C.
[0308] .sup.1H NMR (C.sub.6D.sub.6) .delta. 1.08 (dd, 12 H), 3.43
(m, 2H), 5.47 (m, 1H), 6.16 (d, 1H), 7.0-7.8 (m, 14H), 8.2 (d, 1H),
8.5-8.6 (m, 4H), ppm. .sup.13C NMR (CDCl.sub.3) 24.68, 28.22,
68.87, 120.56, 122.89, 123.63, 123.73, 124.07, 124.1, 125.5,
125.59, 126.24, 126.42, 126.52, 126.76, 126.83, 126.9, 127.05,
127.14, 128.0, 128.55, 129.49, 129.55, 130.67, 130.71, 131.52,
131.55, 132.24, 134.39,137.57, 143.31, 159.1, 162 ppm.
[0309] Catalyst H--(Nme.sub.2).sub.3:
[0310] Inside of a dry box, six different teflon-screw capped,
glass pressure tube reactors are each charged with
Hf(Nme.sub.2).sub.4 (1.55 g, 4.37 mmol, overall 9.3 g, 26.2 mmol),
10 mL of toluene and the ligand isolated from the previous
procedure above (2.1 g, 3.68 mmol, overall 12.6 g, 22.1 mmol). The
tightly sealed reactors are removed from the dry box and placed in
a heater block with the temperature set at 125.degree. C. The
reactor tubes are heated overnight (.about.16 h). The cooled tubes
are taken into the dry box and the contents of the reactor tubes
are combined in a 500 mL round bottom flask. The flask is placed
under vacuum to remove the dimethylamine and toluene. The light
yellow/green solid which is left is rinsed with .about.125 mL of
cold pentane and filtered, yielding 13.6 g of a light yellow powder
for a yield of 65%.
[0311] Catalyst H:
[0312] The reaction is performed inside of a dry box. A 500 mL jar
is charged with 250 mL of pentane and the hafnium amide isolated in
the procedure outlined immediately above (13.6 g, 15.5 mmol). The
mixture is cooled to -40.degree. C. To the stirring mixture is
slowly added 70 mL of a 2.0 M trimethyl aluminum (140 mmol) in
hexane solution. After 3 h the reaction becomes yellow with a fine,
powder precipitating from the mixture. The mixture is then cooled
to -40.degree. C. and filtered. The initially collected product is
rinsed with 2.times.60 mL of cold pentane. 10.24 g Catalyst H is
isolated (84% yield) with a purity of >99% by .sup.1H NMR.
Synthesis of Armeenium Borate
[methylbis(hydrogenatedtallowalkyl)ammonium tetrakis (pentafluoro
phenyl) borate]
[0313] Armeenium borate can be prepared from ARMEEN.RTM. M2HT
(available from Akzo-Nobel), HCl, and Li [B(C.sub.6F.sub.5).sub.4]
according to Example 2 of U.S. Pat. No. 5,919,983.
General 1 Gallon Continuous Solution Propylene/Ethylene
I. Copolymerization Procedure
[0314] Purified toluene solvent, ethylene, hydrogen, and propylene
are supplied to a 1 gallon reactor equipped with a jacket for
temperature control and an internal thermocouple. The solvent feed
to the reactor is measured by a mass-flow controller. A variable
speed diaphragm pump controls the solvent flow rate and increases
the solvent pressure to the reactor. The propylene feed is measured
by a mass flow meter and the flow is controlled by a variable speed
diaphragm pump. At the discharge of the pump, a side stream is
taken to provide flush flows for the catalyst injection line and
the reactor agitator. The remaining solvent is combined with
ethylene and hydrogen and delivered to the reactor. The ethylene
stream is measured with a mass flow meter and controlled with a
Research Control valve. A mass flow controller is used to deliver
hydrogen into the ethylene stream at the outlet of the ethylene
control valve. The temperature of the solvent/monomer is controlled
by use of a heat exchanger before entering the reactor. This stream
enters the bottom of the reactor. The catalyst component solutions
are metered using pumps and mass flow meters, and are combined with
the catalyst flush solvent. This stream enters the bottom of the
reactor, but in a different port than the monomer stream. The
reactor is run liquid-full at 500 psig with vigorous stirring. The
process flow is in from the bottom and out of the top. All exit
lines from the reactor are steam traced and insulated.
Polymerization is stopped with the addition of a small amount of
water, and other additives and stabilizers can be added at this
point. The stream flows through a static mixer and a heat exchanger
in order to heat the solvent/polymer mixture. The solvent and
unreacted monomers are removed at reduced pressure, and the product
is recovered by extrusion using a devolatilizing extruder. The
extruded strand is cooled under water and chopped into pellets. The
operation of the reactor is controlled with a process control
computer.
EXAMPLE 1
Propylene/Ethylene Polymerization using Metallocene Catalyst E
(Comparative)
[0315] The general procedure for the 1 gallon continuous solution
polymerization outlined above was employed. A catalyst solution
containing 2.6 ppm Zr from Catalyst E was prepared and added to a 4
L catalyst storage tank. This solution was combined in a continuous
stream with a continuous stream of a solution containing Armeenium
tetrakis(pentafluorophenyl)borate in toluene and a continuous
stream of a solution of PMAO-IP in toluene to give a ratio of total
Ti:B:Al of 1:1.2:30. The activated catalyst solution was fed
continuously into the reactor at a rate sufficient to maintain the
reactor temperature at approximately 80 degrees C. and a polymer
production rate of approximately 3 pounds an hour. The polymer
solution was continuously removed from the reactor exit and was
contacted with a solution containing 100 ppm of water for each part
of the polymer solution, and polymer stabilizers (i.e., 1000 ppm
Irgaphos 168 and 1000 ppm Irganox 1010 per part of the polymer).
The resulting exit stream was mixed, heated in a heat exchanger,
and the mixture was introduced into a separator where the molten
polymer was separated from the solvent and unreacted monomers. The
resulting molten polymer was extruded and chopped into pellets
after being cooled in a water bath. For this example, the propylene
to ethylene ratio was 22.0. Product samples were collected over 1
hour time periods, after which time the melt flow rate was
determined for each sample. FIG. 9 is a .sup.13C NMR of Comparative
Example 1, and it demonstrates the absence of regio-error peaks in
the region around 15 ppm.
EXAMPLES 2-6
[0316] Examples 2-6 were conducted similar to Example 1 except as
otherwise noted in Tables 2-6-1 and 2-6-2 below. Catalyst E is
listed for comparative purposes. FIG. 8 is the .sup.13C NMR
spectrum of the propylene/ethylene copolymer product of Example 2.
FIGS. 2A and 2B show a comparison of the DSC heating traces of the
propylene/ethylene copolymers of Comparative Example 1 and Example
2. TABLE-US-00006 TABLE 2-6-1 Polymerization Conditions POLY LBS/
Reactor SOLV C2 C3 H2 HR pro- TEMP FLOW FLOW FLOW FLOW duction
Example DEG C. LB/HR LB/HR LB/HR SCCM rate 1 80.5 36.0 0.50 11.00 0
3.13 (comparative) 2 80.5 33.0 0.20 6.00 20.8 3.47 3 80.1 26.0 0.10
6.00 14.1 3.09 4 79.9 26.0 0.20 6.00 20.1 3.25 5 80.0 26.0 0.30
6.00 26.1 3.16 6 80.3 26.0 0.40 6.00 32.1 3.32
[0317] TABLE-US-00007 TABLE 2-6-2 Monomer conversion and activity
catalyst efficiency C3/C2 propylene ethylene concentration g metal
Example Catalyst ratio conversion conversion ppm(metal) per g
polymer 1 E 22.00 25.7% 64.8% 2.6 6,145,944 (comparative) 2 G 30.17
53.1% 99.1% 25.6 235,823 3 H 61.07 48.7% 98.4% 55.0 225,666 4 H
30.34 49.7% 99.0% 55.0 259,545 5 H 20.17 46.8% 98.6% 55.0 259,282 6
H 15.00 48.0% 98.7% 55.0 278,579
[0318] TABLE-US-00008 TABLE 2-6-3 Summary of Polymer Analysis Data
DSC MFR Density Cryst. (%) Tg Tc, o Tc, p Example (g/10 min)
(kg/dm3) from density (.degree. C.) (.degree. C.) (.degree. C.) 1
72 0.8809 37.9 -26.1 52.3 47.6 2 1.7 0.8740 29.6 -24.8 59.0 49.3 3
2.2 0.8850 42.8 -10.0 76.6 64.5 4 2.3 0.8741 29.7 -23.2 50.8 41.6 5
2 0.8648 18.3 -27.1 30.4 10.9 6 2.0 0.8581 9.9 -29.6 -- --
[0319] TABLE-US-00009 TABLE 2-6-4 Summary of Polymer Analysis Data
cont'd .DELTA.Hc Cryst. (%) Tm, p Tm, e .DELTA.Hf Cryst. (%)
Example (J/g) (from Hc) (.degree. C.) (.degree. C.) (J/g) (from Hf)
1 40.8 24.7 91.9 114.3 52.1 31.6 2 27.1 16.4 64.5 128.9 38.0 23.0 3
45.0 27.3 102.2 145.7 65.3 39.6 4 30.6 18.5 67.4 145.6 42.9 26.0 5
8.7 5.3 50.0 119.4 13.0 7.9 6 -- -- -- -- -- --
[0320] TABLE-US-00010 TABLE 2-6-5 Summary of Polymer Analysis Data
cont'd Regio-errors Ex- 14-16 Mw am- Ethylene Ethylene ppm Mn (kg/
ple (wt %)* (mol %)* (mol %)* (kg/mol) mol) MWD 1 9.5 13.6 0.00
58.5 117.4 2.0 2 8.2 11.8 0.24 132.6 315.7 2.4 3 5.6 8.2 0.46 146.0
318.3 2.2 4 8.2 11.8 0.34 138.5 305.7 2.2 5 11.1 15.8 0.35 6 13.2
18.6 0.37 127.5 306.8 2.4
[0321] TABLE-US-00011 TABLE 2-6-6 Summary of Polmer Analysis Data
cont'd Example % mm* % mr* % rr* 1 98.55 0 1.45 2 98.23 1.09 5.68 3
94.3 2.21 3.43 4 96.37 0 3.63 5 95.3 0.0 4.66 6 95.17 0 4.83
*corrected PPE + EPE
EXAMPLES 7-8
Homopolymerization of Propylene using Catalyst B and C
[0322] Examples 7-8 were conducted similar to Example 1 without
ethylene. The procedure was similar to Example 1 with exceptions
noted in Tables 7-8-1 and 7-8-2 below. FIG. 6 shows the .sup.13NMR
spectrum of the propylene homopolymer product of Example 7 prepared
using catalyst G. FIG. 7 shows the .sup.13C NMR spectrum of the
propylene homopolymer product of Example 8 prepared using catalyst
H. Both spectra show a high degree of isotacticity, and the
expanded Y-axis scale of FIG. 7 relative to FIG. 6 shows more
clearly the regio-error peaks. FIGS. 13A and 13B show the DSC
heating and cooling traces of the propylene homopolymer of Example
8. TABLE-US-00012 TABLE 7-8-1 Reactor Conditions and Catalyst
Activity Reactor SOLV C3 H2 POLY catalyst efficiency TEMP FLOW FLOW
FLOW LBS/HR propylene concentration g metal Example DEG C. LB/HR
LB/HR SCCM WEIGHED Catalyst conversion ppm(metal) per g polymer 7
99.8 33.1 6.00 1.9 2.30 G 38.3% 25.6 111,607 8 100.3 26.0 6.00 2.6
2.57 H 42.8% 32.5 100,987
[0323] TABLE-US-00013 TABLE 7-8-2 Polymer Analysis DSC MFR Density
Cryst. (%) Tg Tc, o Tc, p Mn Mw Example (g/10 min) (kg/dm3) from
density (.degree. C.) (.degree. C.) (.degree. C.) (kg/mol) (kg/mol)
MWD 7 1.9 0.8995 59.7 -6.0 104.2 100.4 114.6 350.8 2.7 8 2.5 0.9021
62.7 -8.1 105.7 103.3 125.5 334.0 2.7
[0324] TABLE-US-00014 TABLE 7-8-3 Polymer Analaysis Continued
.DELTA.Hc Cryst. (%) Tm, p Tm, e .DELTA.Hf Cryst. (%) Regio-errors
Example (J/g) (from Hc) (.degree. C.) (.degree. C.) (J/g) (from Hf)
14-16 ppm(mol %)* % mm** % mr** % rr** 7 76.9 46.6 139.7 153.5 93.7
56.8 2.69 92.12 5.79 2.08 8 83.6 50.7 144.5 158.2 100.6 61.0 2.36
93.93 4.45 1.62 *determined by NMR **corrected PPE + EPE
EXAMPLE 9
[0325] This example demonstrates the calculation of B values for
certain of the Examples disclosed herein. The polymer from
Comparative Example 1 is analyzed as follows. The data was
collected using a Varian UNITY Plus 400 MHz NMR spectrometer,
corresponding to a .sup.13C resonance frequency of 100.4 MHz.
Acquisition parameters were selected to ensure quantitative
.sup.13C data acquisition in the presence of the relaxation agent.
The data was acquired using gated .sup.1H decoupling, 4000
transients per data file, a 7 sec pulse repetition delay, spectral
width of 24,200 Hz and a file size of 32K data points, with the
probe head heated to 130.degree. C. The sample was prepared by
adding approximately 3 mL of a 50/50 mixture of
tetrachloroethane-d2/orthodichlorobenzene that is 0.025M in
chromium acetylacetonate (relaxation agent) to 0.4 g sample in a 10
mm NMR tube. The headspace of the tube was purged of oxygen by
displacement with pure nitrogen. The sample was dissolved and
homogenized by heating the tube and its contents to 150.degree. C.,
with periodic refluxing initiated by heat gun.
[0326] Following data collection, the chemical shifts were
internally referenced to the mmmm pentad at 21.90 ppm.
[0327] For propylene/ethylene copolymers, the following procedure
is used to calculate the percent ethylene in the polymer. Integral
regions are determined as follows: TABLE-US-00015 TABLE 9-1
Integral Regions for Calculating % Ethylene Region designation Ppm
Integral area A 44-49 259.7 B 36-39 73.8 C 32.8-34 7.72 P 31.0-30.8
64.78 Q Peak at 30.4 4.58 R Peak at 30 4.4 F 28.0-29.7 233.1 G
26-28.3 15.25 H 24-26 27.99 I 19-23 303.1
[0328] Region D is calculated as follows: D=P-(G-Q)/2. [0329]
Region E is calculated as follows: E=R+Q+(G-Q)/2.
[0330] The triads are calculated as follows: TABLE-US-00016 TABLE
9-2 Traid Calculation PPP = (F + A - 0.5D)/2 PPE = D EPE = C EEE =
(E - 0.5G)/2 PEE = G PEP = H Moles P = (B + 2A)/2 Moles E = (E + G
+ 0.5B + H)/2
For this example, the mole % ethylene is calculated to be 13.6 mole
%.
[0331] For this example, the triad mole fractions are calculated to
be as follows: TABLE-US-00017 TABLE 9-3 Triad Mole Calculation PPP
= 0.6706 PPE = 0.1722 EPE = 0.0224 EEE = 0.0097 PEE = 0.0442 PEP =
0.0811
From this, the B value is calculated to be:
(0.172+0.022+0.044+0.081)/2(0.136.times.0.864)=1.36
[0332] In a similar manner, the B values for the following examples
are calculated to be: TABLE-US-00018 TABLE 9-4 B-Value Calculation
Example B Value Comparative 1 1.36 2 1.68 3 1.7 4 1.78 6 1.7
EXAMPLE 10
[0333] Table 10 is a summary showing the skewness index, S.sub.ix,
for inventive and prior art samples. All of the samples were
prepared and measured as described in Table C in the Description of
the Preferred Embodiments and entitled Parameters Used for TREF.
The copolymers of the invention have a skewness index greater than
about (-1.2). The results from Table 10 are represented graphically
in FIG. 14.
[0334] The inventive examples show unusual and unexpected results
when examined by TREF. The distributions tend to cover a large
elution temperature range while at the same time giving a
prominent, narrow peak. In addition, over a wide range of ethylene
incorporation, the peak temperature, T.sub.Max, is near 60.degree.
C. to 65.degree. C. In the prior art, for similar levels of
ethylene incorporation, this peak moves to higher elution
temperatures with lower ethylene incorporation.
[0335] For conventional metallocene catalysts the approximate
relationship of the mole fraction of propylene, X.sub.p, to the
TREF elution temperature for the peak maximum, T.sub.Max, is given
by the following equation:
Log.sub.e(X.sub.p)=-289/(273+T.sub.max)+0.74
[0336] For the inventive copolymers, the natural log of the mole
fraction of propylene, LnP, is greater than that of the
conventional metallocenes, as shown in this equation:
LnP>-289/(273+T.sub.max)+0.75
[0337] TABLE-US-00019 TABLE 10 Summary of Skewness Index Results
P/E* Elution Temperature Sample Catalyst Ethylene Content of Peak
maximum No. Type (Mole %) (.degree. C.) S.sub.ix 10-1 Catalyst H
8.2 61.4 0.935 10-2 Catalyst J 8.9 60.8 -0.697 10-3 Catalyst J 8.5
61.4 -0.642 10-4 Catalyst J 7.6 65.0 0.830 10-5 Catalyst J 7.6 65.0
0.972 10-6 Catalyst J 8.6 61.4 0.804 10-7 Catalyst J 9.6 60.2
-0.620 10-8 Catalyst J 12.4 60.2 0.921 10-9 Catalyst J 8.6 60.8
-0.434 10-10 Catalyst J 8.6 62.0 1.148 10-11 Catalyst H -- 57.8
1.452 10-12 Catalyst J -- 78.2 1.006 10-13 Catalyst H 4.4 80.0
-1.021 10-14 Catalyst E 7.6 80.6 -1.388 10-15 Catalyst E 10.0 70.4
-1.278 10-16 Catalyst E 10.7 66.2 -1.318 10-17 Catalyst F 11.1 69.2
-1.296 10-18 Catalyst E 10.6 65.6 -1.266
EXAMPLE 11
[0338] DSC analysis shows that propylene/ethylene copolymers
produced by a solution polymerization process using a
nonmetallocene, metal-centered, pyridal-amine ligand catalyst have
melting behavior that differs in surprising ways from
propylene/ethylene copolymers produced by metallocene
polymerization processes that are known in the art. The different
melting behavior of these copolymers compared to that of copolymers
that are known in the art not only demonstrates the novelty of
these materials, but also can be used to infer certain advantages
of these materials for some applications. The novel aspects of the
melting behavior of these copolymers and their associated utility
are discussed below, after first describing the DSC analysis
method.
[0339] Any volatile materials (e.g., solvent or monomer) are
removed from the polymer prior to DSC analysis. A small amount of
polymer, typically five to fifteen milligrams, is accurately
weighed into an aluminum DSC pan with lid. Either hermetic or
standard type pans are suitable. The pan containing the sample is
then placed on one side of the DSC cell, with an empty pan with lid
placed on the reference side of the DSC cell. The DSC cell is then
closed, with a slow purge of nitrogen gas through the cell during
the test. Then the sample is subjected to a programmed temperature
sequence that typically has both isothermal segments and segments
where the temperature is programmed to increase or decrease at a
constant rate. Results that are presented here were all obtained
using heat-flux type DSC instruments manufactured by TA Instruments
(e.g., Model 2910 DSC). The measurement principles underlying
heat-flux DSC are described on page 16 of Turi, ibid. The primary
signals generated by such instruments are temperature (units:
.degree. C.) and differential heat flow (units: watts) into or out
of the sample (i.e., relative to the reference) as a function of
elapsed time. Melting is endothermic and involves excess heat flow
into the sample relative to the reference, whereas crystallization
is exothermic and involves excess heat flow out of the sample.
These instruments are calibrated using indium and other
narrow-melting standards. Calibration ensures that the temperature
scale is correct and for the proper correction of unavoidable heat
losses.
[0340] Temperature programs for DSC analysis of semi-crystalline
polymers involve several steps. Although the temperature programs
used to generate the data presented here differed in some details,
the critical steps were maintained constant throughout. The first
step is an initial heating to a temperature sufficient to
completely melt the sample; for polypropylene homopolymers and
copolymers, this is 210.degree. C. or higher. This first step also
helps insure excellent thermal contact of the polymer sample with
the pan. Although details of this first step differed for data
presented here--for example, the rate of heating, the upper
temperature, and the hold time at the upper temperature--in all
cases the choices were sufficient to achieve the principal
objectives of this step, of bringing all samples to a common
completely melted starting point with good thermal contact. The
second step involves cooling at a constant rate of 10.degree.
C./min from an upper temperature of at least 210.degree. C. to a
lower temperature of 0.degree. C. or less. The lower temperature is
chosen to be at or slightly below the glass transition temperature
of the particular propylene polymer. The rate of crystallization
becomes very slow at the glass transition temperature; hence,
additional cooling will have little effect on the extent of
crystallization. This second step serves to provide a standard
crystallization condition, prior to examining subsequent melting
behavior. After a brief hold at this lower temperature limit,
typically one to three minutes, the third step is commenced. The
third step involves heating the sample from a temperature of
0.degree. C. or lower (i.e., the final temperature of the previous
step) to 210.degree. C. or higher at a constant rate of 10.degree.
C./min. This third step serves to provide a standard melting
condition, as preceded by a standard crystallization condition. All
the melting behavior results presented here were obtained from this
third step, that is, from the second melting of the sample.
[0341] The output data from DSC consists of time (sec), temperature
(.degree. C.), and heat flow (watts). Subsequent steps in the
analysis of melting endotherms are as follows. First, the heat flow
is divided by the sample mass to give specific heat flow (units:
W/g). Second, a baseline is constructed and subtracted from the
specific heat flow to give baseline-subtracted heat flow. For the
analyses presented here, a straight-line baseline is used. The
lower temperature limit for the baseline is chosen as a point on
the high temperature side of the glass transition. The upper
temperature limit for the baseline is chosen as a temperature about
5-10.degree. C. above the completion of the melting endotherm.
Although a straight-line baseline is theoretically not exact, it
offers greater ease and consistency of analysis, and the error
introduced is relatively minor for samples with specific heats of
melting of about 15-20 Joules per gram or higher. Employing a
straight-line baseline in lieu of a more theoretically correct
baseline does not substantively affect any of the results or
conclusions presented below, although the fine details of the
results would be expected to change with a different prescription
of the instrumental baseline.
[0342] There are a number of quantities that can be extracted from
DSC melting data. Quantities that are particularly useful in
demonstrating differences or similarities among different polymers
are: (1) the peak melting temperature, T.sub.max (.degree. C.),
which is the temperature at which the baseline-subtracted heat flow
is a maximum (here the convention is that heat flow into the sample
is positive); (2) the specific heat of melting, .DELTA.h.sub.m
(J/g), which is the area under the melting endotherm obtained by
integrating the baseline-subtracted heat flow (dq/dt) (W/g) versus
time between the baseline limits; (3) the specific heat flow
(dq/dt).sub.max (W/g) at the peak melting temperature; (4) the peak
specific heat flow normalized by the specific heat of melting,
{(dq/dt).sub.max/.DELTA.h.sub.m} (sec.sup.-1); (5) the first moment
T.sub.1 of the melting endotherm, defined and calculated as
described below; (6) the variance V.sub.1 (.degree. C..sup.2) of
the melting endotherm relative to the first moment T.sub.1, defined
and calculated as described below; and (7) the square root of the
variance, V.sub.1.sup.1/2 (.degree. C.), which is one measure of
the breadth of the melting endotherm.
[0343] Treatment of the melting endotherm as a distribution is a
useful way to quantify its breadth. The quantity that is
distributed as a function of temperature is the baseline-subtracted
heat flow (dq/dt). That this is also a distribution of temperature
is made explicit using the calculus chain rule,
(dq/dt)=(dq/Dt)(Dt/dt) where (Dt/dt) is the heating rate. The
standard definition of the first moment T.sub.1 of this
distribution is given by the following equation, where the
integrations are carried out between the baseline limits. All
integrations are most reliably performed as (dq/dt) versus time, as
opposed to the alternative (dq/Dt) versus temperature. In the
following equation, (dq/dt) and T are the specific heat flow and
temperature at time t. T 1 = .intg. T ( d q / d t ) .times. d t
.intg. ( d q / d t ) .times. d t ##EQU4## The variance V.sub.1
relative to the first moment is then standardly defined as: V 1 =
.intg. ( T - T 1 ) 2 ( d q / d t ) .times. d t .intg. ( d q / d t )
.times. d t ##EQU5## Both V.sub.1 and V.sub.1.sup.1/2 are measures
of the breadth of the melting endotherm.
[0344] Results of DSC analyses of both inventive and comparative
polymers are shown in Table 11-1. All the samples are
propylene/ethylene copolymers, with the exception of Samples 1-4
and 17 which are homopolymers. Polymers 1-16 were made using
Catalyst H in a solution process. Polymers 17-27 were made with
Catalyst E in a solution process. An idea of the precision of the
experimental method plus the data analysis procedure is provided by
replicates (polymers 17, 20, and 22) and by the consistency of
results for sets of polymers that were synthesized under nearly
identical conditions (polymers 1-4, 7-9, 10-12, and 13-16).
[0345] Differences in melting behavior are most easily seen with
the aid of figures. FIG. 15 compares the melting endotherms of
Samples 8 and 22a. These two propylene/ethylene copolymers have
nearly equivalent heats of melting and mole percent ethylene
contents, about 71 J/g and 8 mole %. However, despite these
similarities, the melting behavior of the inventive copolymer
(Sample 8) is surprisingly different than that of the comparative
copolymer (Sample 22a). The melting endotherm of Sample 8 is
shifted towards lower temperatures and significantly broadened,
when comparing at equivalent heat of melting. These changes in
melting behavior are unique to and characteristic of the copolymers
of this invention.
[0346] Comparison at equivalent heats of melting is particularly
meaningful and relevant. This is because equivalent heats of
melting implies approximately equal levels of crystallinity, which
in turn implies that the room temperature moduli should be similar.
Therefore, at a given modulus or stiffness, the copolymers of this
invention possess usefully broadened melting ranges compared to
typical non-inventive copolymers.
[0347] FIGS. 16-20, which are derived from the results in Table
11-1, further highlight the differences in melting behavior for the
copolymers of this invention compared to typical copolymers. For
all five of these figures, quantities are plotted as functions of
the heat of melting, which as described above is an especially
meaningful and relevant basis for making intercomparisons and
inferring utility. For these plots, data have broken into two
series based on the catalyst type used to make the polymer, either
metallocene or nonmetallocene type.
[0348] FIG. 16 demonstrates how the peak melting temperature is
shifted towards lower temperature for the copolymers of this
invention. All the changes in melting behavior, of which this shift
in peak melting temperature is but one example, imply that there
are differences in the crystalline structure at the level of
crystal lamellae or other type of primary crystalline elements. In
turn, such differences in crystalline structure can most reasonably
be attributed to differences in microstructure, for example, the
different type of mis-insertion errors or the higher B values that
characterize the polymers of this invention. Regardless of the
exact nature of the microstructural features that give rise to the
changes in melting behavior, the changes are in and of themselves
evidence that the copolymers of this invention are novel
compositions.
[0349] FIG. 17 which shows a plot of the temperature T.sub.1%c at
which there is approximately 1% residual crystallinity,
demonstrates another surprising aspect of the melting behavior of
the copolymers of this invention. The factor that is used to
convert specific heat of melting into nominal weight %
crystallinity is 165 J/g=100 weight % crystallinity. (Use of a
different conversion factor could change details of the results but
not substantive conclusions.) With this conversion factor, the
total crystallinity of a sample (units: weight % crystallinity) is
calculated as 100% times .DELTA.h.sub.m divided by 165 J/g. And,
with this conversion factor, 1% residual crystallinity corresponds
to 1.65 J/g. Therefore, T.sub.1%c is defined as the upper limit for
partial integration of the melting endotherm such that
.DELTA.h.sub.m minus the partial integral equals 1.65 J/g, where
the same lower limit and baseline are used for this partial
integration as for the complete integration. Surprisingly, for
nonmetallocene-catalyzed copolymers as compared to
metallocene-catalyzed copolymers, this 1% residual crystallinity
temperature shifts downward less rapidly with increase in ethylene
level (i.e., with decrease in the heat of melting). This behavior
of T.sub.1%c is similar to that of the final temperature of melting
T.sub.me.
[0350] FIG. 18, which shows the variance relative to the first
moment of the melting endotherm as a function of the heat of
melting, demonstrates directly the greater breadth of the melting
endotherm for the copolymers of this invention.
[0351] FIG. 19, which shows the maximum heat flow normalized by the
heat of melting as a function of the heat of melting, further
demonstrates the broadening of the melting endotherm. This is
because, at equivalent heat of melting, a lower peak value implies
that the distribution must be broadened to give the same area.
Roughly approximating the shape of these melting curves as a
triangle, for which the area is given by the formula one-half times
the base times the height, then b1/b2=h2/h1. The inventive
copolymers show as much as a four-fold decrease in height, implying
a significant increase in breadth.
[0352] FIG. 20 illustrates a useful aspect of the broader melting
range of the inventive polymers, namely that the rate at which the
last portion of crystallinity disappears (units: weight %
crystallinity per .degree. C.) is significantly lower than for
metallocene polymers.
[0353] The data in Table 11-2 demonstrate in practical terms the
utility of this broadening of the melting endotherm. Entries in
Table 11-2 illustrate: (1) the extent to which a greater fraction
of melting occurs at lower temperatures, which is important for
heat seal and bonding applications, and which is greater for the
inventive copolymers; and (2) the extent to which crystallinity
remains at higher temperatures and the rate at which the final
portion of crystallinity disappears, which can be important for
fabrication operations such as thermoforming, foaming, blow
molding, and the like, both of which are greater for the inventive
copolymers. TABLE-US-00020 TABLE 11-1 Melting Results from DSC
ethylene .DELTA.h.sub.m T.sub.max T.sub.1
(dq/dt).sub.max/.DELTA.h.sub.m T.sub.1%c R.sub.f Sample* (mole %)
(J/g) (.degree. C.) (.degree. C.) (sec.sup.-1) V.sub.1 (.degree.
C..sup.2) (.degree. C.) (**) 11-1-1 0.0 90.4 139.0 123.5 0.0109 416
143.0 1.60 11-1-2 0.0 94.3 138.8 122.2 0.0105 505 143.1 1.54 11-1-3
0.0 94.0 139.4 122.4 0.0105 505 143.3 1.60 11-1-4 0.0 95.9 139.5
121.4 0.0102 576 143.4 1.60 11-1-5 1.5 92.4 138.2 118.4 0.0105 630
142.0 1.48 11-1-6 4.3 85.0 120.7 99.2 0.0045 716 135.0 0.40 11-1-7
8.2 67.5 85.9 83.8 0.0023 909 139.7 0.19 11-1-8 8.2 71.2 93.0 84.4
0.0025 835 137.5 0.19 11-1-9 8.2 74.6 108.2 87.0 0.0029 790 134.6
0.23 11-1-10 11.8 51.6 71.7 69.3 0.0024 790 124.4 0.14 11-1-11 11.8
52.5 74.8 69.4 0.0025 781 123.7 0.14 11-1-12 11.8 51.9 73.9 69.4
0.0025 802 124.3 0.14 11-1-13 15.8 24.0 55.2 66.7 0.0031 667 112.0
0.10 11-1-14 15.8 28.7 55.2 66.3 0.0026 795 118.0 0.10 11-1-15 15.8
27.6 55.6 66.0 0.0026 783 116.4 0.10 11-1-16 15.8 26.9 55.2 66.4
0.0026 769 115.7 0.10 11-1-17a 0.0 120.7 160.3 145.3 0.0104 457
165.9 1.43 11-1-17b 0.0 123.9 159.8 144.5 0.0105 486 165.2 1.54
11-1-18 . . . 90.3 140.6 125.0 0.0076 419 146.1 1.21 11-1-19 . . .
91.3 139.0 123.9 0.0068 374 145.5 1.05 11-1-20a 4.2 110.2 137.7
121.8 0.0094 337 144.3 0.95 11-1-20b 4.2 96.5 137.9 121.1 0.0100
451 142.7 1.38 11-1-21 . . . 94.6 136.7 120.3 0.0086 385 140.5 1.43
1-1-22a 8.0 71.4 117.5 105.8 0.0081 197 124.8 0.74 11-1-22b 8.0
69.7 117.0 103.4 0.0080 271 122.8 1.00 11-1-23 . . . 70.1 110.3
91.0 0.0062 512 115.9 0.95 11-1-24 . . . 55.9 97.0 78.7 0.0052 436
103.9 0.67 11-1-25 . . . 19.8 63.0 61.1 0.0044 188 80.1 0.25
11-1-26 . . . 18.2 56.6 58.8 0.0049 158 75.3 0.27 *Samples 11-1-1
to -4 made with catalyst G, samples -5 to -16 with catalyst H, and
-17 to -24 with catalyst E. **Units for R.sub.f: weight %
crystallinity per .degree. C.
[0354] TABLE-US-00021 TABLE 11-2 Broadening of the Melting
Endotherm fraction fraction fraction fraction Starting melted
melted remaining remaining Crystallinity at T.sub.1 - at T.sub.1 -
at T.sub.1 + at T.sub.1 + Sample (weight %) 30.degree. C.
20.degree. C. 20.degree. C. 30.degree. C. 11-2-8 43.2 0.153 0.229
0.249 0.134 (inventive) 11-2-22a 43.3 0.040 0.112 0.019 0.004
(comparative) 11-2-11 31.8 0.143 0.235 0.221 0.131 (inventive)
11-2-25 33.9 0.103 0.170 0.127 0.009 (comparative)
EXAMPLE 12
[0355] FIGS. 10 and 11 report certain elasticity data for the
polymers of this invention and certain comparative polymers. Table
12-1 describes the elastomers.
[0356] The test samples were compression molded specimens. Polymer
in pellet form was compression molded at 190 C. into 1.5 mm thick
sheets. The sheets were cooled by placing each between two platens
at 25 C. under light pressure. The specimens were allowed to age
for at least seven days at ambient conditions before testing.
[0357] Tensile "dog bones" were punched out of the sheets using a
knife shaped according to ASTM D-1708. The first melting behavior
was measured by cutting out a 5 to 10 mg piece of the aged
specimen. The specimen was loaded into an aluminum pan and analyzed
in a differential scanning calorimeter manufactured by TA
Instruments Incorporated. Heating spanned -50 to 230 C. at 10
C./min.
[0358] The specimens were tested in uniaxial tension with a
mechanical test device (Instron Corp.) fitted with pneumatic grips.
The engineering strain rate was 400% per minute. Both strain to
break and multicycle loading strain histories were used. In the
case of multicycle loading, specimens were loaded and unloaded to
various strains (100 to 900%) for up to 10 cycles. No pause was
used between successive cycles.
[0359] Table 12-2 reports the data in FIGS. 10 and 11. The data in
Table 12-2 reports elasticity versus crystallinity for the same
group of elastomers. Crystallinity is an important property in
elastomeric applications because it controls to a large extent the
stiffness (i.e., modulus) of a material. The virgin or unstretched
metallocene polypropylenes exhibit elasticity versus crystallinity
similar to the homogeneous polyethylene and ethylene-stryene
elastomers, while the elastomeric polymers of this invention
exhibit higher elasticity at the same crystallinity. Even after
pre-stretching, the elastomeric polymers of this invention continue
to exhibit superior elasticity at the same crystallinity as
compared to both the metallocene propylenes and the homogeneous
polyethylene and ethylene-stryene elastomers. The polymers of this
invention demonstrate similar elasticity after stretching as do
commercial grade SEBS polymers, e.g., Krayton G-1657.
TABLE-US-00022 TABLE 12-1 Elastomers DSC Polymer Comonomer
Crystallinity Samples Description (wt. %) (mol %) (wt. %) 1 P/E*
polymer 11 16 18 2 P/E* polymer 13 19 10 A metallocene-catalyzed --
-- 21 propylene-ethylene copolymer B metallocene-catalyzed -- -- 4
propylene-ethylene copolymer C ethylene-octene copolymer 41 15 14 D
Affinity EG8100 35 12 6 E ethylene-styrene copolymer 41 16 5 F
Kraton G-1657 (SEBS) -- -- --
[0360] TABLE-US-00023 TABLE 12-2 Elasticity Values of the Data in
FIGS. 10 and 11 virgin Pre-stretched average Polymer 1st cycle 10th
cycle (>1 cycle) 1 0.57 0.88 0.88 2 0.75 0.97 0.97 A 0.49 0.85
0.83 B 0.71 0.99 0.99 C 0.52 0.78 0.76 D 0.64 0.92 0.89 E 0.71 0.92
0.90 F 0.90 0.98 0.99
EXAMPLE 13
[0361] The P* and P/E* polymers reported in Table 13-1 (Samples
13-1 through 13-4 were prepared with Catalyst J in a solution
polymerization process) were fed into a Killion blown film line
available from Killion Extruders INC. under model designation
KN-125. During the film blowing, the Killion line was equipped with
a 1.5 inch (3.81 cm) diameter screw, 3 inch (7.62 cm) die diameter,
and a 70 mil (1778 micron) die gap. The extruder is 50 inch (125
cm) long with a length to diameter ratio (L/D) of 30. The
temperature profile is listed as follows: 370, 370, 380, 380, 390,
425, 395, 396 F for zone 1, 2, 3, 4, screen changer, die 1 and die
2. The melt temperature is about 425 F. (218.2 C.) with a blow up
ratio (BUR) of 2.0 and an output rate of 10 lb/h. The screw speed
was 65 rpm, the back pressure 1650 psi, the screw amperage 7 amp,
and the layflat about 9.5 inches.
[0362] The resulting films were 2.0 mil (50 micron) in thickness
and film properties were measured according to standard ASTM
methods as shown in Table 13-2.
[0363] For comparison, various commercially or experimentally
available Ziegler-Natta catalyzed random polypropylene resins, also
shown in Table 1 (Samples 13-1-C through 13-5-C), were also
fabricated with Killion line under similar operating parameters as
above. Film properties were also measured according to standard
ASTM methods as shown in Table 13-2.
[0364] Film properties for all above films are shown in Table 13-3.
As can be seen from these data, P/E* copolymer films in which the
P/E* copolymer comprises at least 5 wt % ethylene have a machine
direction (MD) tear greater than 100 g/mil. In addition, those P/E*
copolymer films in which the P/E* copolymer comprises at least 5 wt
% ethylene have a haze value of less than 10%, and a 45 degree
gloss greater than 65%. The dart impact strength of these films is
greater than 200 g. TABLE-US-00024 TABLE 13-1 Resin I MFR
Co-monomer type Co-monomer % 13-1-1 2 0 13-1-2 2 Ethylene 3 13-1-3
2 Ethylene 5 13-1-4 2 Ethylene 8 13-1-1-C 2 Ethylene 0.5 13-1-2-C 2
Ethylene 3.2 13-1-3-C 7 Ethylene 5.5 13-1-4-C 2 Ethylene 3 13-1-5-C
5 1-Butene 12
[0365] TABLE-US-00025 TABLE 13-2 Test Methods Test Methods Dart-A
ASTM D-1709 Elmendorf Tear-B ASTM D1922 Haze ASTM D1003 Tensile,
ASTM D882 Gloss-45 degree ASTM D2457 MFR ASTM 1238
[0366] TABLE-US-00026 TABLE 13-3 Film Property Comparison
Normalized Resin/ wt % MD-tear, properties comonomer MD-tear, g
CD-tear, g Dart, g Haze, % Gloss-45 g/mil 13-1 0 13 25 60 28 30 7
13-2 3 16 52 60 5.5 75 8 13-3 5 290 1063 640 5 74 145 13-4 8 740
1327 756 2 88 375 13-1-C 0.5 14 46 60 34 23 7 13-2-C 3 19 56 60 2.4
88 9 13-3-C 3.2 14.8 60 60 16.3 44.1 9 13-4-C 5.5 33 48 69 6.8 72.5
16 13-5-C 12 23 43 68 10 68 12
EXAMPLE 14
[0367] A commercially available Ziegler-Natta polypropylene,
nucleated NA-11 (methylene-bis-(4,6-di-tert-butylphenyl) phosphate
sodium salt manufactured by Asahi Denka), was used as a base resin
for a blending study. Various P/E* copolymers and commercially
available polyethylene resins were melt blended with the Z-N PP at
a ratio indicated in Table 14. The melt-blended materials were then
fed into the Killion line described in Example 13 to produce blown
films. The film properties were measured as described in Example
13.
[0368] The film properties for these blended films are shown in
Table 14. The films made by blending the P/E* copolymer into Z-N PP
and comprising P/E* copolymer and that have at least 5 wt % of
ethylene in the overall blend have machine direction tear greater
than 100 g/mil. In addition, these P/E* copolymer films comprising
at least 5 wt % ethylene have a haze value less than 10%, a 45
degree gloss greater than 65%, and dart impact strength greater
than 200 grams. TABLE-US-00027 TABLE 14 Ex 14-A Ex 14-B Ex 14-C
Comp-1 Comp-2 Result Name H110/50% H110/50% H110/70% H110-02
H110/30% (13 wt % E) (11 wt % E) (11 wt % E) PF1140 Gloss 45 deg
83.4 82.1 75.8 63.6 74.3 Haze 4.1 3.3 5.3 7.9 5.1 Dart A 486.0
433.5 600.5 60.0 60.0 CD-tear, 500.7 546.0 758.2 38.7 118.0
Thickness 2.8 3.0 2.7 1.9 1.8 Normalized CD- 181.2 185.5 285.2 20.1
65.1 tear, g/mil MD-tear, g 582.8 1065.0 696.4 16.0 17.2 Thickness,
mil 2.95 2.84 2.66 1.95 1.58 Normalized MD- 197.7 377.6 265.4 8.3
11.0 tear, g/mil H110 is a Z-N random PP containing 0.5 wt %
ethylene, an MFR of 2 and nucleated with 1000 ppm NA-11. PF1140 is
an ethylene-octene copolymer with a density of 0.896 g/cc and an MI
of 1.6 manufactured by The Dow Chemical Company.
EXAMPLE 15
[0369] The data in Tables 15-1 and 15-2 and FIGS. 21 and 22 show
that the films of this invention exhibit desirable cling properties
when attached to either another film of this invention or a film of
polyethylene. The films had an A/B structure with the A layer
comprising 15 wt % of the film. The films were 23-27 microns thick.
The A layer was the cling layer. The films were tested for cling in
accordance with ASTM D4649.
[0370] Table 15-1 shows the cling values when two A/B film
structures were tested with the A layer of the first film in
contact with the B layer of the second film. The clings values were
normalized to make 100% cling values for Film Nos. 15-1-AB and
15-2-AB.
[0371] The resins identified as PP-0125, 1952, 0136 1734 are P/E*
copolymers made in a solution polymerization process using Catalyst
J. The Attane SC 4106 is a polyethylene resin with an MFR of 3.3
g/10 min and a density of 0.912 g/cc, and the Attane SC 4107 is a
polyethylene resin with an MFR of 4 g/10 min and a density of 0.904
g/cc. DOWLEX SC 2106 is a polyethylene resin with an MFR of 3.3
g/10 min and a density of 0.917 g/cc. All three MFR's are measured
at 190 C. and are manufactured by The Dow Chemical Company.
TABLE-US-00028 TABLE 15-1 Cling Properties, B/A-B/A Test Film No.
Resin A Resin B Cling % 15-1-AB Attane SC4106 Dowlex SC2106 100
15-2-AB Attane SC4107 Dowlex SC2106 100 15-3-AB PP-0125 Dowlex
SC2106 83 (5% E; MFR 8) 15-4-AB PP-1952 Dowlex SC2106 147 (8% E;
MFR 8) 15-5-AB PP-0136 Dowlex SC2106 112 (3% E; MFR 25) 15-6-AB
PP-1734 Dowlex SC2106 374 (11% E; MFR 25)
[0372] Table 15-2 shows the cling values when two A/B film
structures were tested with the A layer of the first film in
contact with the A layer of the second film. The clings values were
normalized to make 100% cling values for Film Nos. 15-1-AA and
15-2-AA. TABLE-US-00029 TABLE 15-2 Cling Properties, B/A-A/B Test
Film No. Resin A Cling % 15-1-AA Attane SC4106 100 15-2-AA Attane
SC4107 100 15-3-AA PP-0125 68 (5% E; MFR 8) 15-4-AA PP-1952 134 (8%
E; MFR 8) 15-5-AA PP-0136 103 (3% E; MFR 25) 15-6-AA PP-1734 500
(11% E; MFR 25)
EXAMPLES 16 AND 17
P/E* Containing Sealant Compositions
[0373] The following examples show the use of the P/E* polymers of
the invention as sealant compositions for sealing applications. The
sealant applications include, but are not limited to, films,
laminates, and other articles for use in such applications as,
biaxially oriented polypropylene film processes (BOPP) film
sealants, cast film sealants, tie-layer for various film and
laminate structures, such as bags, sacks, wraps, surface contact
protecters, and snacks containers. The films can be monolayer or
multilayer and may be formed by various processes, such as, blown
film processes, calandered film processes, cast film processes,
BOPP, tenter film processes, and sheet and profile extrusion
processes.
[0374] The sealant compositions may be comprised of P/E* polymers
alone, or may be comprised of P/E* polymers blended with other
alpha-olefin homopolymers and/or copolymers. The preferable
alpha-olefin polymers to blend with the P/E* polymers are propylene
homopolymers, copolymers of propylene and other alpha-olefins, such
as ethylene, 1-butene, 1-pentane, 1-hexane, 4-methyl pentane,
1-heptane, and 1-octene.
[0375] When used alone for the sealant compositions, the P/E*
polymers preferably have at least 3% by weight of units derived
from ethylene, more preferably at least about 5% by weight of units
derived from ethylene, further more preferably from about 6 wt. %
to 10 wt % units derived from ethylene, most preferably from about
7 wt. % to 9 wt % units derived from ethylene.
[0376] When blended with another propylene ethylene copolymer, the
blend preferably has from about 4 wt % to 9 wt % of units derived
from ethylene, more preferably, from about 5 wt % to 9 wt % of
units derived from ethylene, and the P/E* polymer preferably has
from about 7 wt % to 15 wt % of units derived from ethylene, more
preferably from about 8 wt % to 14 wt % of units derived from
ethylene, further more preferably from about 9 wt % to 13 wt % of
units derived from ethylene, most preferably from about 10 wt % to
12 wt % of units derived from ethylene.
[0377] For the following examples, the hot tack of the films was
measured using the "JB Instrument Hot Tack Test Method," which
measures the force required to separate a heat seal before the seal
has had a chance to fully cool (crystallize). This test simulates
the filling of material into a pouch or bag before the seal has had
a chance to completely cool.
[0378] The "JB Instrument Hot Tack Test Method" is a test method
using a JB Instrument Hot Tack Tester according to the following
conditions: TABLE-US-00030 Specimen Width: 25.4 mm SealingTime: 0.5
seconds Sealing Pressure: 0.27 N/mm/mm Delay Time: 0.2 seconds Peel
Speed: 250 mm/seconds Number of Samples per 5 Temperature
Temperature Increments: 5.degree. C.
[0379] The heat seal strength of sample films was measured using
the "JB Instrument Heat Seal Strength Test Method," which is
designed to measure the force required to separate a seal after the
material has completely cooled to 23.degree. C. The film samples
were exposed to a relative humidity of 50 percent and a temperature
of 23.degree. C. for a minimum of 24 hours prior to testing.
[0380] The seal strength of the film samples was determined using
an Instron Tensile Tester Model #1122 according to the following
test conditions: TABLE-US-00031 Direction of Pull: 90.degree. to
seal Crosshead Speed: 500 mm/minute Full Scale Load: 5 kg Number of
Samples/Threshold: 1 percent of FSL Break Criterion: 80 percent
Gauge Length: 2.0 inches (50.8 millimeters) Sample Width: 1.0 inch
(25.4 millimeters)
[0381] Heat seal initiation temperature is defined as the minimum
temperature for 2 lb/in (0.4 Kg/cm) seal strength.
[0382] All of the films of Examples 16 and 17 are blown films made
in accordance with the descriptions set forth in Examples 13 and
14.
[0383] The following resins were used in Examples 16 and 17: [0384]
A. P/E* S1 is a propylene ethylene copolymer containing 3 wt % of
units derived from ethylene and is made with Catalyst J using a
loop polymerization process as described in U.S. Pat. No.
5,977,251. [0385] B. P/E* S2 is a propylene ethylene copolymer
containing 5 wt % of units derived from ethylene and is made with
Catalyst J using a loop polymerization process as described in U.S.
Pat. No. 5,977,251. [0386] C. P/E* S3 is a propylene ethylene
copolymer containing 8 wt % of units derived from ethylene and is
made with Catalyst J using a loop polymerization process as
described in U.S. Pat. No. 5,977,251. [0387] D. P/E* S4 is a
propylene ethylene copolymer containing 11 wt % of units derived
from ethylene and is made with Catalyst J using a loop
polymerization process as described in U.S. Pat. No. 5,977,251.
[0388] E. P/E* S5 is a propylene ethylene copolymer containing 13
wt % of units derived from ethylene and is made with Catalyst J
using a loop polymerization process as described in U.S. Pat. No.
5,977,251. [0389] F. H308-02Z is a Z-N catalyzed random copolymer
of propylene and ethylene having 0.5 wt % units derived from
ethylene available from The Dow Chemical Company.
Propylene-ethylene copolymers having less than 1 wt % of units
derived from ethylene are sometimes hereinafter referred to as
"mini-random propylene-ethylene copolymers". [0390] G. SR256M is a
Z-N catalyzed random copolymer of propylene and ethylene having 3
wt % units derived from ethylene available from Basell. These types
of random copolymers are often referred to as "RCP PP". [0391] H.
PF1140 is a single-site catalyzed ethylene/1-octene copolymer
having a melt index of 1.6 and a density of 0.896 g/cc and which is
available from The Dow Chemical Company. [0392] I. H110-02Z is a
Z-N catalyzed random copolymer of propylene and ethylene having 0.5
wt % units derived from ethylene and 1000 ppm NA-11 nucleator
(available from Asahi-Denka) which is available from The Dow
Chemical Company.
EXAMPLE 16
P/E* Sealants
[0393] Referring to FIG. 23, it can be seen that P/E* resins having
5 wt % of units derived from ethylene have much better heat seal
behavior than typical Z-N-catalyzed propylene-ethylene copolymers
(designated as 3 and 5 wt % E, ZNPP) and even exhibits better heat
seal behavior than a Z-N-catalyzed propylene-1-butene copolymer
(designated as 12 wt % B, ZNPP) having 12 wt % of units derived
from 1-butene. Significantly, the P/E* resin exhibits a heat seal
initiation temperature of 100 C.
[0394] Referring to FIG. 24, it can be seen that the hot tack
window for the P/E* resins is broader than typical Z-N-catalyzed
propylene-alpha-olefin copolymers.
EXAMPLE 17
P/E*/Alpha Olefin Polymer Blends
[0395] Referring to FIG. 25, it can be seen that the heat seal
behavior of a blend of Z-N-catalyzed mini-random propylene-ethylene
copolymer and an ethylene/1-octene copolymer normally behaves
according to the weighted average of the components of the blend.
In particular, the heat seal initiation temperature of such blends
is normally much reduced compared to the heat seal initiation
temperature of the mini-random alone.
[0396] Referring to FIGS. 26 and 27, it can be seen that the P/E*
polymers do not follow the normal blending rules when blended with
a mini-random propylene ethylene copolymer. It can be seen from
FIGS. 26 and 27 that the heat seal behavior of blends of P/E*
copolymer with propylene homopolymers and with mini-random
propylene-ethylene copolymers are relatively insensitive to the
ethylene content of the P/E* copolymer and/or the amount of P/E*
copolymer that makes up the blend.
[0397] FIG. 28 shows that the modulus of the blend decreases as the
wt % of P/E* copolymer in the blend increases. FIGS. 26-28 together
show that a lower modulus sealant composition can be made with P/E*
copolymers that will have a relatively high heat seal initiation
temperature. The lower modulus will result in less stiff articles
of manufacture. This is particularly important for retort
applications and like applications where a higher heat seal
initiation temperature is desired, but a stiff sealing area is
undesirable.
[0398] Now referring to FIGS. 29 and 30, it can be seen that blends
of P/E* copolymers with random propylene-ethylene copolymers having
greater than 1 wt % units derived from ethylene have greatly
reduced seal initiation temperatures as compared to the random
propylene-ethylene copolymer and as compared to a blend of a
mini-random propylene-ethylene copolymer with P/E* copolymers.
[0399] FIG. 31 shows that nucleating agents, for example NA-11, are
preferably added to blends of two or more P/E* copolymers to
improve the heat seal behavior of such blends. Primarily such
nucleating agents lower the seal initiation temperature while
maintaining the seal strength.
[0400] FIG. 32 shows that as the blends of P/E* copolymers having a
weight percent of units derived from ethylene of from 5.5 to 6.5 wt
% have very good hot tack performance.
[0401] FIGS. 32 and 33 show that blends of P/E* copolymers with
mini-random propylene-ethylene copolymers have very good hot tack
performance at higher temperatures, but worse hot tack performance
at lower temperatures, as compared with random propylene-ethylene
copolymers having greater than 2% by weight of units derived from
ethylene.
EXAMPLE 18
[0402] Films made in accordance with the description of Example 13
were tested for oxygen permeability (O.sub.2 Permeability) and
water vapor transmission rate (WVTR). The O.sub.2 permeability was
measured in accordance with ASTM D3985-81 at an O.sub.2
concentration of 1% at 1 atmosphere and 23.degree. C. The WVTR was
measured in accordance with ASTM F1249-90 at 37.8.degree. C. The
results are shown in Table 18.
[0403] As can be seen from Table 18, the P/E* polymers of the
instant invention have a relatively higher WVTR and O.sub.2
permeability than a comparative Z-N-catalyzed propylene-ethylene
copolymer having equivalent ethylene levels. The enhanced
permeability is particularly beneficial for film applications that
take advantage of higher O.sub.2 permeability and WVTR, such as
fresh produce overwrap. TABLE-US-00032 TABLE 18 O.sub.2
permeability WVTR P/E* cc - Mil/100 in.sup.2 .times. day @ gm -
Mil/100 in.sup.2 .times. day Ethylene % wt 23.degree. C. @ 37.8 C
0% -- 0.76 5 394 1.9 8 707 2.68
EXAMPLE 19
[0404] It is believed that the P/E* polymers will have lower shrink
initiation temperatures than comparable Ziegler-Natta (Z-N)
catalyzed propylene-ethylene copolymers having an equivalent amount
of units derived from ethylene. In addition to the other physical
properties listed for the P/E* polymers, this will lead to shrink
films that are operable at a lower temperature. For example, this
can be advantageous for food packaging preparation procedures. The
shrink initiation temperature for this application is defined as
the temperature that results in at least 20% shrinkage in either
the cross-direction (CD) or machine direction (MD), as determined
in accordance with ASTM 2732.
[0405] The good compatibility of the P/E* polymers with polyolefins
(in particular polyethylenes) and the P/E* polymers excellent
optical properties (as compared with typical Z-N-catalyzed
polypropylenes) results in advantaged blends of P/E* polymers with
polyolefins for shrink film applications. In particular, blends of
P/E* polymers with low density polyethylene (LDPE) will provide
shrink films having a better balance of optical and shrink
properties compared to blends of LDPE with comparative
Z-N-catalyzed propylene-ethylene copolymers.
[0406] Further, the same advantages set forth above will apply to
multi-layer structures (such as multi-layer film structures) where
the P/E* polymer and the polyolefin are not blended together, but
are contained in adjacent layers of the multi-layer structure.
[0407] Although the invention has been described in considerable
detail, this detail is for the purpose of illustration. Many
variations and modifications can be made on the invention as
described above without departing from the spirit and scope of the
invention as described in the appended claims. All publications
identified above, specifically including all U.S. patents and
allowed U.S. patent applications, are incorporated in their
entirety herein by reference.
* * * * *