# Patent

## Title
Impact resistant polymer blends of crystalline polypropylene and partially crystalline, low molecular weight impact modifiers

## Abstract

Polymer blends that exhibit good impact resistance comprise a crystalline polypropylene matrix and a partly crystalline copolymer impact modifier with a molecular weight lower than that of the matrix polymer. The matrix polymer can comprise any crystalline propylene homo- or copolymer. The impact modifying copolymers are characterized as comprising at least about 60 weight percent (wt %) of units derived from propylene and, in certain embodiments, as having at least one, preferably two or more, of the following properties: (i) 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 of the copolymer is at least about 3 wt %, (iii) a skewness index, Six, greater than about −1.20, (iv) a DSC curve with a Tme that remains essentially the same and a Tmax that decreases as the amount of comonomer 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.

## Background
CROSS REFERENCE TO RELATED APPLICATION
This application is a division of U.S. patent application Ser. No. 10/289,122, filed Nov. 5, 2002, which also claims the benefit under 35 USC §119(e) of U.S. Provisional Application Nos. 60/338,881 and 60/378,203 filed Nov. 6, 2001 and May 5, 2002.


FIELD OF THE INVENTION
This invention relates to polymer blends. In one aspect, the invention relates to polymer blends comprising a polypropylene matrix and an impact modifier while in another aspect, the invention relates to polymer blends in which the matrix comprises an isotactic homopolymer of propylene and the impact modifier comprises an isotactic copolymer of propylene, ethylene and/or one or more unsaturated comonomers. In yet another aspect, the invention relates to processes for preparing and using the polypropylene impact copolymers, and articles made from the copolymers.
BACKGROUND OF THE INVENTION
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 rubber, e.g., copolymer of propylene and ethylene and/or one or more α-olefins, is used, or a blend of crystalline polypropylene with one or more rubbers that exhibit good impact resistance, e.g., propylene/ethylene (P/E) copolymer, or ethylene-propylene (EP) and/or ethylene-propylene-diene (EPDM) rubber. Crystalline polypropylene has an isotactic structure, and it is readily produced using a Ziegler-Natta (Z-N) or a metallocene catalyst, or a constrained geometry catalyst (CGC). For purposes of this disclosure, P/E copolymers comprise 50 weight percent or more propylene while EP 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.
Polypropylene impact compositions typically comprise (i) one or ore matrix polymers, e.g., a crystalline polypropylene homo- or copolymer, and (ii) one or more impact modifiers, typically a rubber. The matrix provides the stiffness and optical properties, and the impact modifier provides the toughness. The addition of an impact modifier generally causes a reduction in stiffness and optics of the total blend compared to the stiffness and optics of the matrix by itself. This reduction in optics can be minimized by carefully designing the solubility of the impact modifier with regard to the matrix.
The solubility of a propylene-ethylene impact modifier in the matrix is determined by composition and molecular weight. To achieve sufficient toughness, a minimal level of ethylene is required in the propylene-ethylene impact modifier, which then leaves the molecular weight as the parameter to influence solubility. Decreasing molecular weight of the impact modifier increases the solubility of the impact modifier in the matrix. However, impact modifiers with low molecular weight may migrate to the surface of fabricated parts and show blooming which can reduce the optic performance significantly.
The addition of the impact modifier can be in-situ (e.g., reactors in series) or off-line via compounding (e.g., physically blending the matrix and impact modifying resins). Impact modifiers can be more accurately designed via single site catalysis (e.g., by a metallocene) than via Ziegler-Natta catalysis. Additionally, impact modifiers prepared via single site catalysis have a narrow molecular weight distribution (MWD), and thus have less low molecular weight extractables than impact modifiers prepared via Ziegler-Natta catalysis.
SUMMARY OF THE INVENTION
According to this invention, polymer blends that exhibit good impact resistance comprise a (i) crystalline polypropylene matrix, and (ii) partially crystalline copolymer impact modifier that has a molecular weight lower than that of the matix polymer. The matrix polymer can comprise any crystalline propylene homo- or copolymer. The impact modifier is a polymer, typically a copolymer or terpolymer, of propylene and ethylene and/or one or more unsaturated comonomers, e.g., C4-20 α-olefins, C4-20 dienes, styrenic compounds, etc. Impact modifiers of propylene and ethylene and/or one or more unsaturated comonomers are typically prepared using a (i) metallocene catalyst, or (iii) nonmetallocene, metal-centered, heteroaryl ligand catalyst. Impact modifiers of propylene and ethylene and/or one or more unsaturated comonomers prepared using a nonmetallocene, metal-centered, heteroaryl ligand catalyst are designated in this disclosure as P/E* copolymers.
Typically, the crystalline polypropylene matrix comprises at least about 50 percent by weight of the polymer blend. If clarity and/or stiffness are the important properties of the blend, then the crystalline polypropylene comprises at least about 60, preferably at least about 70 and more preferably at least about 80, weight percent of the blend based upon the total weight of the blend.
In a first embodiment, the impact modifying polymers have at least one of a (i) percent crystallinity (defined as 100× the heat of fusion as determined by DSC divided by 165 J/g) typically of about 55 to greater than (>) 0, preferably of about 50 to >0, more preferably of about 45 to >0, and even more preferably of about 40 to >0, (ii) melt flow rate (MFR) typically of about 0.01 to about 1000, preferably of about 0.02 to about 100, more preferably of about 0.02 to about 80, and even more preferably of about 0.02 to 50, and (iii) an MWD narrower than a comparable polymer prepared with a Ziegler-Natta (Z-N) catalyst. “A comparable polymer” has the same meaning as it does for the X-ray property defined below. Typically, the percent crystallinity of the impact modifying polymers is at least about 0.1, preferably at least about 1 and more preferably at least about 3.
In a second embodiment, the impact modifier is a copolymer or terpolymer of propylene, ethylene and, optionally, one or more unsaturated comonomers, e.g., C4-20 α-olefins, C4-20 dienes, vinyl aromatic compounds (e.g., styrene), etc. These polymers 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 polymers are also characterized as having at least one of the following properties: (i) 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 polymer is at least about 3 wt %, (iii) a skewness index, Six, greater than about −1.20, (iv) a DSC curve with a Tme that remains essentially the same and a Tmax that decreases as the amount of comonomer, i.e., the units derived from ethylene and/or the unsaturated comonomer(s), in the polymer is increased, and (v) an X-ray diffraction pattern that reports more gamma-form crystals than a comparable polymer prepared with a Ziegler-Natta (Z-N) catalyst. Typically the polymers of this embodiment are characterized by at least two of these properties. Certain of the polymers of this embodiment are characterized by at least three of these properties, while other polymers of this embodiment are characterized by at least four or even all five of these properties.
With respect to the X-ray property of subparagraph (v) above, “a comparable polymer” is one having the same monomer composition within 10 wt %, and the same Mw within 10 wt %. For example, if a propylene/ethylene/1-hexene terpolymer 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.
In a third embodiment, the impact modifier is a polymer, typically a copolymer or terpolymer, of propylene and one or more unsaturated comonomers. These polymers 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 polymers are also characterized as having at least one of the following properties: (i) 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 polymer is at least about 3 wt %, (iii) a skewness index, Six, greater than about −1.20, (iv) a DSC curve with a Tme that remains essentially the same and a Tmax that decreases as the amount of comonomer, i.e., the units derived from the unsaturated comonomer(s), in the polymer is increased, and (v) an X-ray diffraction pattern that reports more gamma-form crystals than a comparable polymer prepared with a Ziegler-Natta (Z-N) catalyst. Typically the polymers of this embodiment are characterized by at least two of these properties. Certain of the polymers 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.
In a fourth embodiment, the invention is a blend in which the matrix polypropylene is characterized as having a 13C NMR peaks corresponding to a regio-error at about 14.6 and about 15.7 ppm, the peaks of about equal intensity and, optionally, substantially isotactic propylene sequences, i.e., the sequences have an isotactic triad (mm) measured by 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 %. In this disclosure, occasionally these propylene homopolymers are referred to as “P* homopolymers” or a similar term. The impact modifier of this embodiment is at least one polymer of the propylene/ethylene and propylene/unsaturated comomoner polymers described in the second and third embodiments of this invention (occasionally referred to in this disclosure, individually and collectively, as a “P/E* copolymer” or a similar term). The blend is, of course, a heterophasic mix in which the polypropylene matrix polymer is the continuous phase and the impact modifying polymer is the discontinuous or dispersed phase. P/E* copolymers are a unique subset of PIE copolymers.
In a fifth embodiment, one or both blend components is itself a blend of one or more polymers. The polypropylene matrix polymer can be a blend of two or more polypropylenes (either or both of which are homo- or copolymers), and either or both of which can exhibit 13C NMR peaks corresponding to a regio-error at about 14.6 and about 15.7 ppm, the peaks of about equal intensity and, optionally, substantially isotactic propylene sequences. The relative amounts of each can vary widely. Alternatively, the polypropylene matrix polymer can be a blend of two or more crystalline polypropylenes in combination with one or more other crystalline polymers, e.g., high density polyethylene (HDPE). In this embodiment, the other crystalline polymer is sufficiently compatible with the crystalline polypropylene such that the blend of these matrix polymers form a substantially homogeneous continuous phase when in combination with the impact modifying copolymer. Typically, the crystalline polypropylene comprises at least about 50 percent by weight of the matrix polymer blend.
Similarly, the impact modifying copolymer can be a blend of two or more P/E* copolymers, or one or more P/E* copolymers in combination with one or more other polymers, e.g., an EP or EPDM rubber. The relative amounts of each component of the these blends can also vary widely, although preferably the one or more P/E* polymer comprises at least about 50 percent by weight of the impact modifying polymer blend. Unlike the crystalline matrix polymers, the one or more other impact modifying polymer need not be compatible with the one or more P/E* polymers such that they form a substantially homogeneous blend. Since the impact modifying polymers form the dispersed phase within the polypropylene matrix, each impact modifying polymer component can be dispersed separately from one another and/or as a blend of two or more of each other.
In certain embodiments of the invention, blends comprising a crystalline polypropylene matrix and a P/E* impact modifier do not show blooming. In contrast, blends comprising a crystalline polypropylene matrix and an amorphous propylene/ethylene (P/E) impact modifier (containing the same level of ethylene and having the same low molecular weight) do show blooming.
Polypropylene-P/E* polymer blends exhibit much better optics than polypropylene impact polymer blends containing other P/E impact modifiers, such as those prepared via single site catalysis, e.g., with a metallocene, in which the impact modifiers contain the same amount of ethylene. Moreover, certain impact modifying terpolymers exhibit lower haze values than their comparable copolymer counterparts when blended with a crystalline polypropylene in similar amounts and under similar conditions. Additionally, polypropylene-P/E* impact polymer blends exhibit better stiffness than polypropylene/impact polymer blends containing P/E impact modifiers (in which both impact modifiers contain the same amount of ethylene).
In a sixth embodiment, the invention is the use of the polypropylene/impact polymer blends of this invention to make various fabricated articles, particularly molded articles.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the unusual comonomer distribution of a propylene/ethylene (P/E*) copolymer made with a metal-centered, heteroaryl ligand catalyst.
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.
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.
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.
FIG. 5 shows a comparison of a TREF curve for a conventional metallocene-catalyzed P/E copolymer and a P/E* copolymer.
FIG. 6 shows the 13C NMR spectrum of the P* homopolymer product of Example 7, prepared using Catalyst G. This spectrum shows the high degree of isotacticity of the product.
FIG. 7 shows the 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.
FIG. 8 shows the 13C NMR Spectrum of the P/E* copolymer product of Example 2 prepared using Catalyst G.
FIG. 9 shows the 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.
FIGS. 10A–J show the chemical structures of various catalysts.
FIGS. 11A–B show the DSC heating and cooling traces of the P* homopolymer of Example 8, prepared using Catalyst H.
FIG. 12 shows a comparison of the skewness index for the P/E* copolymer and several P/E copolymers.
FIG. 13 compares the melting endotherms of Samples 8 and 22a of Example 11.
FIG. 14 demonstrates the shift in peak melting temperature towards lower temperature for samples of the copolymers of Example 11.
FIG. 15 is a plot of the temperature at which approximately 1 percent crystallinity remains in DSC samples of Example 11.
FIG. 16 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.
FIG. 17 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.
FIG. 18 illustrates that the rate at which the last portion of crystallinity disappears in the P/E* polymers is significantly lower than for metallocene polymers.



DESCRIPTION OF THE PREFERRED EMBODIMENTS
Crystalline Polypropylene Matrix
The polypropylene used as the matrix polymer in the practice of this invention can be any suitable crystalline propylene homopolymer or copolymer. If a copolymer, typically it contains less than 20, more preferably less than 10 and even more preferably less than about 5, mole percent comonomer, e.g., an α-olefin having up to about 20, preferably up to about 12 and more preferably up to about 8, carbon atoms. Typically the α-olefin is ethylene. If the polypropylene is a copolymer, then it can be random, block or graft. If the matrix is a blend of propylene polymers, the amount of each component of the blend can vary widely ranging from 100 weight percent homopolymer, to a blend of a homopolymer with one or more crystalline propylene copolymers, to 100 weight percent propylene copolymer. While the matrix may comprise P* homopolymer, preferably the matrix comprises a majority, more preferably a substantial majority, of a highly crystalline polypropylene prepared by Ziegler-Natta or metallocene catalysis.
Impact Modifying Polymer
One species of impact modifying polymers of this invention are propylene polymers that comprise propylene, ethylene and, optionally, one or more unsaturated comonomers. This species includes both P/E and P/E* polymers. Typically, these polymers 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 polymer. The typical amount of ethylene in these polymers 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 polymers 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 polymer. 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 polymer. 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 polymer.
Another species of impact modifying polymers of this invention comprise propylene and one or more unsaturated comonomers (other than ethylene). This species also includes both P/E and P/E* polymers. These polymers 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 polymer. The one or more unsaturated comonomers of the polymer 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 polymer.
The P/E* polymers are the preferred impact modifying polymers used in the practice of this invention.
Molecular Weight
The weight average molecular weight (Mw) of the impact modifying polymers of this invention can vary widely, but typically it is between about 50,000 and 200,000 (with the understanding that the only limit on the minimum or the maximum Mw is that set by practical considerations). “Low molecular weight”, “low weight average molecular weight”, “low Mw” and similar terms mean a weight average molecular weight of less than about 200,000, more preferably less than about 175,000 and even more preferably less than about 150,000.
Polydispersity
The polydispersity of the impact modifying polymers is typically between about 2 and about 6. “Narrow polydisperity”, “narrow molecular weight distribution”, “narrow MWD” and similar terms mean a ratio (Mw/Mn) of weight average molecular weight (Mw) to number average molecular weight (Mn) of less than about 3.5, typically less than about 3.0.
Impact modifying polymer blends may have a higher polydispersity, depending on the molecular weight of the various components of the blend. In particular, blends produced by any of a number of different multiple reactor processes may have a broad range of polydispersities, from as low as about 2 to as high as 100 or more. Preferably, the Mw/Mn 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
Molecular weight distribution of the 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° C. with the autosampler hot zone at 160° C. and the warm zone at 145° 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° C. with gentle mixing.
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}=KMa 

where Kpp=1.90E-04, app=0.725 and Kps=1.26E-04, aps=0.702.

Differential Scanning Calorimetry

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 of this invention are characterized by a DSC curve with a Tme that remains essentially the same and a Tmax that decreases as the amount of unsaturated comonomer in the copolymer is increased. Tme means the temperature at which the melting ends. Tmax means the peak melting temperature.
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° C. to 290° 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° C., cooling the sample to 140° C. at a cooling rate of 10° C./min followed by keeping the sample isothermally at 140° C. for 1 minute, followed by heating the sample from 140° C. to 180° C. at a heating rate of 110° C./min. The heat of fusion and the onset of melting of the indium sample are determined and checked to be within 0.5° C. from 156.6° 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° C. to −30° C. at a cooling rate of 10° C./min. The sample is kept isothermally at −30° C. for 2 minutes and heated to 30° C. at a heating rate of 10° C./min. The onset of melting is determined and checked to be within 0.5° C. from 0° C.
The polypropylene samples are pressed into a thin film at a temperature of 190° 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 1° C./min to a temperature of about 30° 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° C./min to −40° C., and kept isothermally at that temperature for 3 minutes. Consequently the sample is heated at a rate of 10° 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, Tme, and any other DSC analyses of interest.
B-Value
“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 comononomer, 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.
B is defined for a propylene/ethylene copolymer as:




  B
  =
  
    
      f
      
        (
        
          EP
          +
          PE
        
        )
      
    
    
      2
      ·
      
        F
        E
      
      ·
      
        F
        P
      
    
  




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
      
        (
        
          OP
          +
          PO
        
        )
      
    
    
      2
      ·
      
        F
        O
      
      ·
      
        F
        P
      
    
  




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 P/E* polymers, typically made with an activated nonmetallocene, metal-centered, heteroaryl ligand catalyst, are above about 1.4, typcially 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 polymers of this invention. 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 A







B-Values of Selected Propylene Polymers





















Regio-errors


Cryst.








14–16 ppm


(%)




MFR
Density
Ethylene
(mole %)

Tmax
(from


No
Description
(g/10 min)
(kg/dm 3#)
(mol %)
(average of two)
B
(° C.)
Hf)
Tg (° C.)



















A-1
P/E* via
25.8
0.8864
10.6
0.00
1.40
104.7
37.3
−20.9



Catalyst I


A-2
HPP via
1.9
0.8995
0.0
1.35
None
139.5
48.7
−6.9



Catalyst G


A-3
P/E* via
1.7
0.8740
11.8
0.24
1.67
63.3
24.4
−23.6



Catalyst G


A-4
P/E* via
1.5
0.8703
12.9
0.32
1.66
57.7
21.9
−24.5



Catalyst G


A-5
HPP via
2.5
0.9021
0.0
1.18
none
143.5
61.4
−6.0



Catalyst H


A-6
P/E* via
1.9
0.8928
4.3
0.57
1.77
120.6
48.3
−13.8



Catalyst H


A-7
P/E* via
2.2
0.8850
8.2
0.47
1.71
96.0
40.5
−19.3



Catalyst H


A-8
P/E* via
2.3
0.8741
11.8
0.34
1.79
67.9
27.4
−23.7



Catalyst H


A-9
P/E* via
2
0.8648
15.8
0.24
1.67
53.7
10.5
−27.6



Catalyst H


A-10
P/E* via
2.0
0.8581
18.6
0.18
1.70
none
2.6
−29.9



Catalyst H





Catalyst I is dimethyleamidoborane-bis-η5-(2-methyl-4-napthylinden-1-yl)zirconium η4-1,4,-dipheny-1,3-butadiene.


HPP means polypropylene homopolymer.


Catalysts G, H and I are illustrated in FIGS. 10G, 10H and 10I, respectively.













TABLE B







B-Values of Selected Propylene/Ethylene Copolymers

















Regio-errors








Ethylene
14–16 ppm (mole %)

Tmax
Cryst. (%)


No.
Description
(mol %)
(average of two)
B
(° C.)
(from Hf)
Tg (° C.)

















B-1
P/E* via
1.6
0.37
1.78
138.2
53.9
−8.1



Catalyst H


B-2
P/E* via
7.7
0.38
1.66
105.6
38.9
−18.5



Catalyst H


B-3
P/E* via
7.8
0.41
1.61
107.7
39.6
−18.2



Catalyst H


B-4
P/E* via
12.3
0.31
1.58
74.7
30.7
−22.5



Catalyst H


B-5
P/E* via
14.8
0.21
1.67
90.6
31.2
−22.9



Catalyst H


B-6
P/E* via
12.4
0.31
1.61
67.4
20.8
−26.8



Catalyst H


B-7
P/E* via
14.7
0.30
1.60
78.1
19.9
−25.9



Catalyst H


B-8
P/E* via
33.7
0.00
1.67
none
0.0
−39.2



Catalyst H


B-9
P/E* via
31.3
0.00
1.67
none
0.0
−39.2



Catalyst H


B-10
P/E* via
12.0
0.25
1.61
72.4
33.2
−22.8



Catalyst J


B-11
P/E* via
8.9
0.37
1.63
91.4
40.1
−19.8



Catalyst J


B-12
P/E* via
8.5
0.44
1.68
101.7
38.7
−20.0



Catalyst J


B-13
P/E* via
7.6
0.47
1.68
107.6
43.2
−18.8



Catalyst J


B-14
P/E* via
7.6
0.35
1.64
106.2
42.4
−18.5



Catalyst J


B-15
P/E* via
8.6
0.33
1.64
104.4
41.0
−19.5



Catalyst J


B-16
P/E* via
9.6
0.35
1.65
85.5
38.1
−20.6



Catalyst J


B-17
P/E* via
8.6
0.37
1.63
104.1
41.8
−19.6



Catalyst J


B-18
P/E* via
8.6
0.34
1.62
90.8
40.8
−19.6



Catalyst J


B-19
P/E* via
8.6
0.40
1.58
93.3
41.9
−19.2



Catalyst J





Catalyst J is illustrated in FIG. 10J.






The processes used to produce the P/E* copolymers produce interpolymers 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 propylene/ethylene interpolymers used in the practice of this invention 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
FIGS. 3 and 4 further illustrate the thermal properties of the P/E* polymers. FIG. 3 illustrates that the P/E* polymers have a higher glass transition temperaure (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 Tmax 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.
FIG. 4 illustrates that the P/E* polymers also have a lower Tg at an equivalent ethylene content than a similar 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
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 accuractely determining the weight distribution of fractions.
While TREF was originally applied to copolymers of ethylene and higher α-olefins, it can also be used for the analysis of copolymers of propylene with ethylene (or higher α-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 C







Parameters Used for TREF








Parameter
Explanation





Column type and size
Stainless steel shot with 1.5 cc interstitial



volume


Mass detector
Single beam infrared detector at 2920



cm−1


Injection temperature
150° C.


Temperature control device
GC oven


Solvent
1,2,4-trichlorobenzene


Concentration
0.1 to 0.3% (weight/weight)


Cooling Rate 1
140° C. to 120° C. @ −6.0° C./min.


Cooling Rate 2
120° C. to 44.5° C. @ −0.1° C./min.


Cooling Rate 3
44.5° C. to 20° C. @ −0.3° C./min.


Heating Rate
20° C. to 140° C. @ 1.8° C./min.


Data acquisition rate
12/min









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 the current invention.
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 assymetry is skewness. Equation 1 mathematically represents the skewness index, Six, as a measure of this asymmetry. Equation 1.




  
    S
    ix
  
  =
  
    
      
        Σ
        ⁢
        
          
        
        ⁢
        
          w
          i
        
        *
        
          
            (
            
              
                T
                i
              
              -
              
                T
                Max
              
            
            )
          
          3
        
      
      3
    
    
      
        Σ
        ⁢
        
          
        
        ⁢
        
          w
          i
        
        *
        
          
            (
            
              
                T
                i
              
              -
              
                T
                Max
              
            
            )
          
          2
        
      
    
  




The value, TMax, is defined as the temperature of the largest weight fraction eluting between 50 and 90° C. in the TREF curve. Ti and wi are the elution temperature and weight fraction respectively of an abitrary, ith fraction in the TREF distribution. The distributions have been normalized (the sum of the wi equals 100%) with respect to the total area of the curve eluting above 30° C. Thus, the index reflects only the shape of the crystallized polymer and any uncrystallized polymer (polymer still in solution at or below 30° C.) has been omitted from the calculation shown in Equation 1.
Polymer Definitions and Descriptions
“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., —CH2—CH2—, and not the monomer itself, e.g., CH2═CH2.
“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.
“Random copolymer” means a copolymer in which the monomer is randomly distributed across the polymer chain.
“Impact copolymer”, “impact copolymer blend” and similar terms mean two or more polymers in which one polymer is dispersed in the other polymer, typically one polymer comprising a matrix phase and the other polymer comprising an elastomer phase.
The unsaturated comonomers used in the practice of this invention include, C4-20 α-olefins, especially C4-12 α-olefins such as 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-decene, 1-dodecene and the like; C4-20 diolefins, preferably 1,3-butadiene, 1,3-pentadiene, norbornadiene, 5-ethylidene-2-norbornene (ENB) and dicyclopentadiene; C8-40 vinyl aromatic compounds including sytrene, o-, m-, and p-methylstyrene, divinylbenzene, vinylbiphenyl, vinylnapthalene; and halogen-substituted C8-40 vinyl aromatic compounds such as chlorostyrene and fluorostyrene. For purposes of this invention, ethylene and propylene are not included in the definition of unsaturated comonomers.
The propylene/ethylene impact modifiers 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.
The propylene/unsaturated comonomer impact modifiers 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.
13C NMR
The P* and P/E* polymers 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 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 13C NMR spectra. NMR spectra are determined as follows.
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/α-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 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.
The data is collected using a Varian UNITY Plus 400 MHz NMR spectrometer, corresponding to a 13C resonance frequency of 100.4 MHz. Acquisition parameters are selected to ensure quantitative 13C data acquisition in the presence of the relaxation agent. The data is acquired using gated 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° 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° C. with periodic refluxing initiated by heat gun.
Following data collection, the chemical shifts are internally referenced to the mmmm pentad at 21.90 ppm.
For propylene/ethylene copolymers, the following procedure is used to calculate the percent ethylene in the polymer. Integral regions are determined as follows:







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










Region D is calculated as D=P×(G×Q)/2. Region E=R+Q+(G×Q)/2.








TABLE E





Calculation of Region D


















PPP =
(F + A − 0.5D)/2



PPE =
D



EPE =
C



EEE =
(E − 0.5G)/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










C2 values are calculated as the average of the two methods above (triad summation and algebraic) although the two do not usually vary.
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.
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.
The 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 polymer of this invention, 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 of this invention, 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.
The nature and level of comonomers other than propylene present in the copolymer 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.
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.
The comparison of several 13C NMR sprectra further illustrates the unique regio-errors of the P/E* polymers used in the practice of this invention. FIGS. 6 and 7 are the spectra of the propylene homopolymer products of Exampes 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 P/E* polymers. FIG. 8 is the 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 FIGS. 6 and 7. The presence of the ethylene comonomer does not preclude the occurrence of these unique regio-errors. The 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 used in the practice of this invention.
Melt Flow Rate
The impact modifying copolymers of 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 C4–C20 α-olefins is measured according to ASTM D-1238, condition L (2.16 kg, 230 degrees C.).
Propylene Copolymers
The impact modifying copolymers of this invention include propylene copolymers and terpolymers, sometimes referred to as propylene or propylene-based rubbers. The terpolymers are usually preferred to the copolymers if good optics, i.e., clarity, is an important feature of the matix/rubber blend. Of particular interest are copolymers and terpolymers of 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
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.
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.
The catalysts used to make the P* and P/E* polymers used in the practice of this invention 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.
“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.
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., R1, R2, R3, R4, and R5 can be identical or different (e.g. R1, R2, R3, R4, and R5 may all be substituted alkyls or R1 and R2 may be a substituted alkyl and R3 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.
“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.
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.
“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., CF3), hydroxy, amino, phosphido, alkoxy, amino, thio, nitro, and combinations thereof. Suitable substituted alkyls include, for example, benzyl, trifluoromethyl and the like.
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.
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.
“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.
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.
“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.
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.
“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., CF3), 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.
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.”
“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.
The term “alkoxy” is used herein to refer to the —OZ1 radical, where Z1 is selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocylcoalkyl, 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 Z1 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.
As used herein the term “silyl” refers to the —SiZ1Z2Z3 radical, where each of Z1, Z2, and Z3 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.
As used herein the term “boryl” refers to the —BZ1Z2 group, where each of Z1 and Z2 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.
As used herein, the term “phosphino” refers to the group —PZ1Z2, where each of Z1 and Z2 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.
As used herein, the term “phosphine” refers to the group: PZ1Z2Z3, where each of Z1, Z3 and Z2 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.
The term “amino” is used herein to refer to the group —NZ1Z2, where each of Z1 and Z2 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.
The term “amine” is used herein to refer to the group: NZ1Z2Z3, where each of Z1, Z2 and Z2 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.
The term “thio” is used herein to refer to the group —SZ1, where Z1 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.
The term “seleno” is used herein to refer to the group —SeZ1, where Z1 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.
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.
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
Suitable ligands useful in the catalysts can be characterized broadly as monoanionic ligands having an amine and a heteroaryl or substituted heteroaryl group. The ligands of the catalysts are referred to, for the purposes of this disclosure, as nonmetallocene ligands, and may be characterized by the following general formula:




wherein R1 is very generally selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl and combinations thereof. In many embodiments, R1 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 R1 may be characterized by the general formula:





where Q1 and Q5 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 Q1 or Q5 being bulky (defined as having at least 2 atoms). Q1 and Q5 are independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, aryl, substituted aryl and silyl, but provided that Q1 and Q5 are not both methyl. Q′′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 hetercycloalkyl, 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 —CR2R2R3— and —SiR2R3— with R2 and R3 being independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, 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.

In a more specific embodiment, suitable nonmetallocene ligands may be characterized by the following general formula:




wherein R1 and T are as defined above and each of R4, R5, R6 and R7 is independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof. Optionally, any combination of R1, R2, R3 and R4 may be joined together in a ring structure.

In certain more specific embodiments, the ligands may be characterized by the following general formula:




wherein Q1, Q5, R2, R3, R4, R5, R6 and R7 are as defined above. Q2, Q3 and Q4 are independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof.

In other more specific embodiments, the ligands may be characterized by the following general formula:




wherein R1, R2, R3, R4, R5, and R6 are as defined above. In this embodiment the R7 substituent has been replaced with an aryl or substituted aryl group, with R10, R11, R12 and R13 being independently selected from the group consisting of hydrogen, halo, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; optionally, two or more R10, R11, R12 and R13 groups may be joined to form a fused ring system having from 3–50 non-hydrogen atoms. R14 is selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, halide, nitro, and combinations thereof.

In still more specific embodiments, the ligands may be characterized by the general formula:




wherein R2–R6, R10–R14 and Q1–Q5 are all as defined above.
In certain embodiments, R2 is preferably hydrogen. Also preferably, each of R4 and R5 is hydrogen and R6 is either hydrogen or is joined to R7 to form a fused ring system. Also preferred is where R3 is selected from the group consisting of benzyl, phenyl, 2-biphenyl, t-butyl, 2-dimethylaminophenyl (2-(NMe2)—C6H4—), 2-methoxyphenyl(2-MeO—C6H4—), anthracenyl, mesityl, 2-pyridyl, 3,5-dimethylphenyl, o-tolyl, 9-phenanthrenyl. Also preferred is where R1 is selected from the group consisting of mesityl, 4-isopropylphenyl (4-Pri—C6H4—), napthyl, 3,5-(CF3)2—C6H3—, 2-Me-napthyl, 2,6-(Pri)2—C6H3—, 2-biphenyl, 2-Me-4-MeO-C6H3—; 2-But-C6H4—, 2,5-(But)2—C6H3—, 2-Pri-6-Me-C6H3—; 2-But–6-Me-C6H3—, 2,6-Et2-C6H3—, 2-sec-butyl-6-Et-C6H3— Also preferred is where R7 is selected from the group consisting of hydrogen, phenyl, napthyl, methyl, anthracenyl, 9-phenanthrenyl, mesityl, 3,5-(CF3)2—C6H3—, 2-CF3—C6H4—, 4-CF3—C6H4—, 3,5-F2—C6H3—, 4-F—C6H4—, 2,4-F2—C6H3—, 4-(NMe2)—C6H4—, 3-MeO-C6H4—, 4-MeO—C6H4—, 3,5-Me2-C6H3—, o-tolyl, 2,6-F2—C6H3— or where R7 is joined together with R6 to form a fused ring system, e.g., quinoline.
Also optionally, two or more R4, R5, R6, R7 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, R3 is selected from the group consisting of aryl, substituted aryl, heteroaryl, substituted heteroaryl, primary and secondary alkyl groups, and —PY2 where Y is selected from the group consisting of aryl, substituted aryl, heteroaryl, and substituted heteroaryl.
Optionally within above formulas IV and V, R6 and R10 may be joined to form a ring system having from 5–50 non-hydrogen atoms. For example, if R6 and R10 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 R6 and R10 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 hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof.
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 R2 is selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, aryl, and substituted aryl; and R3 is a phosphino characterized by the formula —PZ1Z2, where each of Z1 and Z2 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 Z1 and Z2 are each independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, heterocycloalkyl, aryl, and substituted aryl; and more specifically phenyl; where Q1, Q3, and Q5 are each selected from the group consisting of alkyl and substituted alkyl and each of Q2 and Q4 is hydrogen; and where R4, R5, R6 and R7 are each hydrogen.
The ligands of the catalysts used to prepare the P/E* polymers used in the practice of this invention may be prepared using known procedures. See, for example, Advanced Organic Chemistry, March, Wiley, New York 1992 (4th Ed.). Specifically, the ligands may be prepared using the two step procedure outlined in Scheme 1.




In Scheme 1, the * represents a chiral center when R2 and R3 are not identical; also, the R groups have the same definitions as above. Generally, R3M2 is a nucleophile such as an alkylating or arylating or hydrogenating reagent and M2 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, R3M2, 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 R3=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:




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 R3M2 to the imine carbon. As shown in Scheme 2 by the *, where R2 and R3 are different, this approach also leads to the formation of a chiral center on the ancillary ligands. For P* and P/E* polymers, this chiral center is important to the tacitity of the polymers. Under some circumstances R3M2 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
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 of this invention 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.
For formulas I, II, III, IV and V, the metal precursor compounds may be characterized by the general formula Hf(L)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 HfCl4, Hf(CH2Ph)4, Hf(CH2CMe3)4, Hf(CH2SiMe3)4, Hf(CH2Ph)3Cl, Hf(CH2CMe3)3Cl, Hf(CH2SiMe3)3Cl, Hf(CH2Ph)2Cl2, Hf(CH2CMe3)2Cl2, Hf(CH2SiMe3)2Cl2, Hf(NMe2)4, Hf(NEt2)4, and Hf(N(SiMe3)2)2Cl2. 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.
For formulas IV and V, the metal precursor compounds may be characterized by the general formula M(L)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 invention uses as pure hafnium or zirconium as is commercially reasonable. Specific examples of suitable hafnium and zirconium precursors include, but are not limited to HfCl4, Hf(CH2Ph)4, Hf(CH2CMe3)4, Hf(CH2SiMe3)4, Hf(CH2Ph)3Cl, Hf(CH2CMe3)3Cl, Hf(CH2SiMe3)3Cl, Hf(CH2Ph)2Cl2, Hf(CH2CMe3)2Cl2, Hf(CH2SiMe3)2Cl2, Hf(NMe2)4, Hf(NEt2)4, and Hf(N(SiMe3)2)2Cl2; ZrCl4, Zr(CH2Ph)4, Zr(CH2CMe3)4, Zr(CH2SiMe3)4, Zr(CH2Ph)3Cl, Zr(CH2CMe3)3Cl, Zr(CH2SiMe3)3Cl, Zr(CH2Ph)2Cl2, Zr(CH2CMe3)2Cl2, Zr(CH2SiMe3)2Cl2, Zr(NMe2)4, Zr(NEt2)4, Zr(NMe2)2Cl2, Zr(NEt2)2Cl2, and Zr(N(SiMe3)2)2Cl2. 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.
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
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 of this invention 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.
Looking first at the 2,1-nonmetallocene metal-ligand complexes, the metal-ligand complexes may be characterized by the following general formula:




wherein T, J′′, R1, 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:





wherein R1, T, R4, R5, R6, R7, 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 are also within the scope of the invention, for example, ethers, amines, thioethers, phosphines and the like are suitable as Lewis bases.

More specifically, the nonmetallocene metal-ligand complexes may be characterized by the general formula:




wherein the variables are generally defined above. Thus, e.g., Q2, Q3, Q4, R2, R3, R4, R5, R6 and R7 are independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxyl, aryloxyl, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; optionally, two or more R4, R5, R6, R7 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 R2, R3 and R4 may be joined together in a ring structure; Q1 and Q5 are selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, aryl, substituted aryl, provided that Q1 and Q5 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.

In other embodiments, the 2,1 metal-ligand complexes can be characterized by the general formula:




wherein the variables are generally defined above.

In still other embodiments, the 2,1 metal-ligand complexes can be characterized by the general formula:




wherein the variables are generally defined above.

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:













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.

Turning to the 3,2 metal-ligand nonmetallocene complexes, the metal-ligand complexes may be characterized by the general formula:




where M is zirconium or hafnium;
R1 and T are defined above;
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
L1 and L2 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.
More specifically, the 3,2 metal-ligand nonmetallocene complexes may be characterized by the general formula:




where M is zirconium or hafnium;
T, R1, R4, R5, R6, L1 and L2 are defined above; and
E′′ is either carbon or nitrogen and is part of an cyclic aryl, substituted aryl, heteroaryl, or substituted heteroaryl group.
Even more specifically, the 3,2 metal-ligand nonmetallocene complexes may be characterized by the general formula:




where M is zirconium or hafnium; and
T, R1, R4, R5, R6, R10, R11, R12, L1 and L2 are defined above.
Still even more specifically, the 3,2 metal-ligand nonmetallocene complexes may be characterized by the general formula:




where M is zirconium or hafnium; and
T, R1, R4, R5, R6, R10, R11, R12, R13, Q1, Q2, Q3, Q4, Q5, L1 and L2 are defined above.
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.
In the above formulas, R10, R11, R12 and R13 are independently selected from the group consisting of hydrogen, halo, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted hetercycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, nitro, and combinations thereof; optionally, two or more R10, R11, R12 and R13 groups may be joined to form a fused ring system having from 3–50 non-hydrogen atoms.
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.
The metal-ligand complexes can be formed by techniques known to those of skill in the art. In some embodiments, R14 is hydrogen and the metal-ligand complexes are formed by a metallation reaction (in situ or not) as shown below in scheme 3:




In scheme 3, R14 is hydrogen (but see above for the full definition of R14 in other embodiments of this invention). 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 L1, L2 and L3 and the other substituents such as Q1–Q5, R2–R6, R10 to R13. In one embodiment, when L1, L2 and L3 are each N(CH3)2, the reaction can proceed by heating the 2,1 complex to a temperature above about 100° C. In this embodiment, it is believed that L1 and L2 remain N(CH3)2 in the 3,2 complex. In another embodiment where L1, L2 and L3 are each N(CH3)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, L1 and L2 are typically converted to the ligand (e.g., alkyl or hydride) stemming from the group 13 reagent (e.g., from trimethyl aluminum, L1 and L2 are each CH3 in the 3,2 complex). The 2,1 complex in scheme 3 is formed by the methods discussed above.
In an alternative embodiment possibly outside the scope of scheme 3, for isotactic polypropylene production, it is currently preferred that R14 is either hydrogen or methyl.
Specific examples of 3,2 complexes include:




The ligands, complexes or catalysts may be supported on an organic or inorganic support. Suitable supports include silicas, aluminas, clays, zeolites, magnesium chloride, polyethyleneglycols, 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 described above 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.
The metal complexes are rendered catalytically active by combination with an activating cocatalyst or by use of an activating technique. Suitable activating cocatalysts for use herein include neutral Lewis acids such as alumoxane (modified and unmodified), C1-30 hydrocarbyl substituted Group 13 compounds, especially tri(hydrocarbyl)aluminum- or tri(hydrocarbyl)boron compounds and halogenated (including perhalogenated) derivatives thereof, having from 1 to 10 carbons in each hydrocarbyl or halogenated hydrocarbyl group, more especially perfluorinated tri(aryl)boron compounds, and most especially tris(pentafluorophenyl)borane; nonpolymeric, compatible, noncoordinating, ion forming compounds (including the use of such compounds under oxidizing conditions), especially the use of ammonium-, phosphonium-, oxonium-, carbonium-, silylium- or sulfonium-salts of compatible, noncoordinating anions, or ferrocenium salts of compatible, noncoordinating anions; bulk electrolysis (explained in more detail hereinafter); and combinations of the foregoing activating cocatalysts and techniques. 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-468,651 (equivalent to U.S. Pat. No. 5,321,106).
The alumoxane used as an activating cocatalyst is of the formula (R4x(CH3)yAlO)n, in which R4 is a linear, branched or cyclic C1 to C6 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 R4 is a linear, branched or cyclic C3 to C9 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, R4 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.
Most preferably, the alumoxane is of the formula (R4x(CH3)yAlO)n, wherein R4 is isobutyl or tertiary butyl, x is about 0.25, y is about 0.75 and n is from about 6 to about 8.
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. 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.
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.
Suitable ion forming compounds useful as cocatalysts include a cation which is a Bronsted acid capable of donating a proton, and a compatible, noncoordinating anion, A−. As used herein, the term “noncoordinating” means an anion or substance which either does not coordinate to the Group 4 metal containing precursor complex and the catalytic derivative derived therefrom, or which is only weakly coordinated to such complexes thereby remaining sufficiently labile to be displaced by a neutral Lewis base. A noncoordinating anion specifically refers to an anion which when functioning as a charge balancing anion in a cationic metal complex does not transfer an anionic substituent or fragment thereof to said cation thereby forming neutral complexes. “Compatible anions” are anions which are not degraded to neutrality when the initially formed complex decomposes and are noninterfering with desired subsequent polymerization or other uses of the complex.
Preferred anions are those containing a single coordination complex comprising a charge-bearing metal or metalloid core which anion is capable of balancing the charge of the active catalyst species (the metal cation) which may be formed when the two components are combined. Also, said anion should be sufficiently labile to be displaced by olefinic, diolefinic and acetylenically unsaturated compounds or other neutral Lewis bases such as ethers or nitrites. Suitable metals include, but are not limited to, aluminum, 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.
In one embodiment, the activating cocatalysts may be represented by the following general formula:

[L*−H]+d[Ad−]

wherein:

L* is a neutral Lewis base;
[L*−H]+ is a Bronsted acid;
Ad− is a noncoordinating, compatible anion having a charge of d−, and
d is an integer from 1 to 3.
More preferably Ad− corresponds to the formula: [M′k+Qn′]d− wherein:
k is an integer from 1 to 3;
n′ is an integer from 2 to 6;
n′−k=d;
M′ is an element selected from Group 13 of the Periodic Table of the Elements; and
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.
In a more preferred embodiment, d is one, i.e., the counter ion has a single negative charge and is A−. Activating cocatalysts comprising boron which are particularly useful in the preparation of these catalysts may be represented by the following general formula:

[L*−H]+[BQ4]−

wherein:

[L*−H]+ is as previously defined;
B is boron in an oxidation state of 3; and
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.
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:

    triethylammonium tetraphenylborate,
    N,N-dimethylanilinium tetraphenylborate,
    tripropylammonium tetrakis(pentafluorophenyl) borate,
    N,N-dimethylanilinium n-butyltris(pentafluorophenyl) borate,
    triethylammonium tetrakis(2,3,4,6-tetrafluorophenyl) borate,
    N,N-diethylanilinium tetrakis(2,3,4,6-tetrafluorophenyl) borate, and
    N,N-dimethyl-2,4,6-trimethylanilinium tetrakis(2,3,4,6-tetrafluorophenyl) borate;
    dialkyl ammonium salts such as:
    di-(i-propyl)ammonium tetrakis(pentafluorophenyl) borate, and
    dicyclohexylammonium tetrakis(pentafluorophenyl) borate;
    tri-substituted phosphonium salts such as:
    triphenylphosphonium tetrakis(pentafluorophenyl) borate,
    tri(o-tolyl)phosphonium tetrakis(pentafluorophenyl) borate, and
    tri(2,6-dimethylphenyl)phosphonium tetrakis(pentafluorophenyl) borate;
    di-substituted oxonium salts such as:
    diphenyloxonium tetrakis(pentafluorophenyl) borate,
    di(o-tolyl)oxonium tetrakis(pentafluorophenyl) borate, and
    di(2,6-dimethylphenyl)oxonium tetrakis(pentafluorophenyl) borate;
    di-substituted sulfonium salts such as:
    diphenylsulfonium tetrakis(pentafluorophenyl) borate,
    di(o-tolyl)sulfonium tetrakis(pentafluorophenyl) borate, and
    di(2,6-dimethylphenyl)sulfonium tetrakis(pentafluorophenyl) borate.


Preferred [L*−H]+ cations are N,N-dimethylanilinium and tributylammonium.
Another suitable ion forming, activating cocatalyst comprises a salt of a cationic oxidizing agent and a noncoordinating, compatible anion represented by the formula:

(Oxe+)d(Ad−)e 

wherein:

Oxe+ is a cationic oxidizing agent having a charge of e+;
e is an integer from 1 to 3; and
Ad− and d are as previously defined.
Examples of cationic oxidizing agents include: ferrocenium, hydrocarbyl-substituted ferrocenium, Ag+, or Pb+2. Preferred embodiments of Ad− are those anions previously defined with respect to the Bronsted acid containing activating cocatalysts, especially tetrakis(pentafluorophenyl)borate.
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:

©+A−

wherein:

©+ is a C1-20 carbenium ion; and
A− is as previously defined.
A preferred carbenium ion is the trityl cation, i.e., triphenylmethylium.
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:

R3Si(X′)q+A−

wherein:

R is C1-10 hydrocarbyl, and X′, q and A− are as previously defined.
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.
Certain complexes of alcohols, mercaptans, silanols, and oximes with tris(pentafluorophenyl)borane are also effective catalyst activators. Such cocatalysts are disclosed in U.S. Pat. No. 5,296,433.
The metal complexes can also be rendered catalytically active by bulk electrolysis or the generation of activating cocatalysts by the electrolysis of a disilane comound in the presence of a source of a noncoordinating compatible anion. This latter technique is more fully disclosed in U.S. Pat. No. 5,625,087.
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.
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. These aluminum compounds can be employed 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.
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.
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. Included in these embodiments is the use of two different nonmetallocene, metal-centered, heteroaryl ligand catalysts. Any catalyst which is capable of copolymerizing one or more olefin monomers to make an interpolymer or homopolymer may be used in conjunction with the nonmetallocene, metal-centered, heteroaryl ligand catalyst. One 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.
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 U.S. Pat. Nos. 6,268,444 and 6,515,155 and in U.S. Patent Application Publication Nos. 2002/0062011, 2003/0004286 and 2002/0165329, and in copending application U.S. Ser. No. 60/393,862. These catalysts tend to have the capability of producing higher molecular weight polymers.
Other catalysts, cocatalysts, catalyst systems, and activating techniques which may be used to make the impact-modifying polymers used in the practice of the invention 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, U.S. Pat. Nos. 5,965,756 and 6,150,297. CGC and other catalysts that make amphorous polymers are not favored for use in this invention.
Process Descriptions
The matrix polymers, including the P* homopolymer, and the impact modifying polymers, including the P/E* copolymers, used in the practice of this invention can be made by any convenient process. In one embodiment, the process reagents, e.g., (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.
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.
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/C4-20 α-olefin copolymer processes of the present invention, the weight ratio of propylene to C4-20 α-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.
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.
The P* and P/E* polymers produced in a single reaction vessel will have the desired MFR, narrow MWD and, if a P/E* polymer, the 13C NMR peaks at 14.6 and 15.7 ppm (the peaks of approximately equal intensity), a high B-value (if a P/E* copolymer), and/or 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.
In one embodiment, the monomers comprise propylene and at least one olefin selected from the group consisting of C4–C10 α-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.
As a practical limitation, slurry polymerization takes place in liquid diluents in which the polymer product is substantially insoluble. Preferably, the diluent for slurry polymerization is one or more hydrocarbons with less than 5 carbon atoms. If desired, saturated hydrocarbons such as ethane, propane or butane may be used in whole or part as the diluent. Likewise the α-olefin comonomer or a mixture of different α-olefin comonomers may be used in whole or part as the diluent. Most preferably, the major part of the diluent comprises at least the α-olefin monomer or monomers to be polymerized.
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 ETM, available from Exxon Chemicals Inc.; cycloalkanes such as cyclopentane, cyclohexane, and methylcyclohexane; and aromatics such as benzene, toluene, xylenes, ethylbenzene and diethylbenzene.
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 impact modifying polymers used in the practice of this invention 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.
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.
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.
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° C., preferably from 75 to 200° C., and most preferably from greater than 95 to 200° C.
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 C4-20 α-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 C4-20 α-olefins into the reactor, optionally with a solvent or diluent, and optionally with a controlled amount of H2; 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).
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.
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 H2.
Applications
The impact-modified blends of this invention possess a balance of stiffness, toughness and optics that is desirable for many end uses. They are particularly preferred for applications where excellent clarity is required in combination with the improved toughness via impact modification. Examples of such applications include extrusion to make cast sheet, cast film and blown film; solid-phase pressure forming and melt thermoforming of cast sheet; and molding processes such as injection molding, rotomolding, and especially extrusion blow molding and injection stretch blow molding. Moreover, certain impact modifying P/E* terpolymers exhibit lower haze values than their comparable P/E* copolymer counterparts when blended with a crystalline polypropylene in similar amounts and under similar conditions.
The impact modifying polymers used in the practice of this invention 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 impact modifiers used in the practice of this invention 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.
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. 10A-B illustrate the chemical structures of various catalysts described in the following examples.
SPECIFIC EMBODIMENTS
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 (C5Me4SiMe2NtBu)Ti(η4-1,3-pentadiene) (Catalyst A, FIG. 10A)
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)titanium1,3-pentadiene (Catalyst B, FIG. 10B)
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-η)-3-(1,3-dihydro-2H-isoindol-2-yl)-1H-inden-1-yl)silanaminato-(2-)-N-)dimethyltitanium (Catalyst C, FIG. 10C)
(1) Preparation of dichloro(N-(1,1-dimethylethyl)-1,1-di(p-tolyl)-1-((1,2,3,3a,7a-η)-3-(1,3-dihydro-2H-isoindol-2-yl)-1H-inden-1-yl)silanaminato-(2-)-N-)-titanium




(A) Preparation of N-(tert-butyl)-N-(1,1-p-tolyl)-1-(3-(1,3-dihydro-2H-isoindol-2-yl)-1H-indenyl)silyl)amine




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.
1H(C6D6) δ: 1.10 (s, 9H), 2.01 (s, 3H), 2.08 (s, 3H), 4.12 (d, 1H, 3JH-H=1.5 Hz), 4.39 (d, 1H, 2JH-H=11.1 Hz), 4.57 (d, 1H, 2JH-H=11.7 Hz), 5.55 (d, 1H, 3JH-H=2.1 Hz), 6.9–7.22 (m, 10H), 7.56 (d, 1H, 3JH-H=7.8 Hz), 7.62 (d, 1H, 3JH-H=6.9 Hz), 7.67 (d, 1H, 3JH-H=7.8 Hz), 7.83 (d, 1H, 3JH-H=7.8 Hz).
13C{1H} (C6D6) δ: 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.
(B) Preparation of N-(tert-butyl)-N-(1,1-p-tolyl)-1-(1,3-dihydro-2H-isoindol-2-yl)-1H-indenyl)silyl)amine, dilithium salt
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-indenyl)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 2×25 mL of hexane, and dried under reduced pressure to give 2.262 g of the product as a yellow powder.
1H(C6D6) δ: 1.17 (s, 9H), 2.30 (s, 6H), 4.51 (s, 4H), 6.21 (s, 1H), 6.47 (m, 2H), 6.97 (d, 4H, 3JH-H=8.1 Hz), 7.15 (m, 2H), 7.23 (m, 2H), 7.50 (m, 1H), 7.81 (d, 4H, 3JH-H=7.8 Hz), 8.07 (d, 1H, 3JH-H=7.2 Hz). 13C{1H} (C6D6) δ: 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.
(C) Preparation of dichloro(N-(1,1-dimethylethyl)-1,1-di-p-tolyl-1-((1,2,3,3a,7a-η)-3-(1,3-dihydro-2H-isoindol-2-yl)-1H-inden-1-yl)silanaminato-(2-)-N-)titanium
In the drybox 1.552 g (4.19 mmol) of TiCl3(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-indenyl)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 PbCl2 (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.
1H (THF-d8) δ: 1.40 (s, 9H), 2.46 (s, 3H), 2.48 (s, 3H), 5.07 (d, 2H, 2JH-H=12.3 Hz), 5.45 (d, 2H, 2JH-H=12.6 Hz), 5.93 (s, 1H), 6.95 (d, 1H, 3JH-H=9.0 Hz), 7.08 (d, 1H, 3JH-H=7.8 Hz), 7.15–7.4 (m, 9H), 7.76 (d, 1H, 3JH-H=7.8 Hz), 7.82 (d, 1H, 3JH-H=7.5 Hz), 8.05 (d, 1H, 3JH-H=8.7 Hz). 13C{1H} (THF-d8) δ: 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.
(2) Preparation of (N-(1,1-dimethylethyl)-1,1-di-p-tolyl-1-((1,2,3,3a,7a-η)-3-(1,3-dihydro-2H-isoindol-2-yl)-1H-inden-1-yl)silanaminato-(2-)-N-)dimethyltitanium




In the drybox 0.50 g of dichloro(N-(1,1-dimethylethyl)-1,1-di-p-tolyl-1-((1,2,3,3a,7a-η)-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° 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.
1H(C6D6) δ: 0.25 (s, 3H), 0.99 (3H), 1.72 (s, 9H), 2.12 (s, 3H), 2.15 (s, 3H), 4.53 (d, 2H, 2JH-H=11.7 Hz), 4.83 (d, 2H, 2JH-H=11.7 Hz), 5.68 (s, 1H), 6.72 (dd, 1H, 3JH-H=8.6 Hz, 3JH-H=6.6 Hz), 6.9–7.2 (m, 11H), 7.30 (d, 1H, 3JH-H=8.6 Hz). 7.71 (d, 1H, 3JH-H=8.5 Hz), 7.93 (d, 1H, 3JH-H=7.8 Hz), 8.11 (d, 1H, 3JH-H=7.8 Hz). 13C{1H} (C6D6) δ: 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, FIG. 10D)
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, FIG. 10E)
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, FIG. 10F)
Catalyst F can be synthesized according to Example 11 of U.S. Pat. No. 5,616,664.
Synthesis of Catalyst G, FIG. 10G
Hafnium tetrakisdimethylamine. 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 LiNMe2 (21 g, 95%, 0.39 mol). HfCl4 (29.9 g, 0.093 mol) is added slowly over 2 h. The temperature reaches 55° 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° C.) receiving flask. This process is performed outside the dry box on a Schlenk line. The material is distilled over at 110–120° C. at 300–600 microns. The 19.2 g of the white solid is collected.
2-formyl-6-naphthylpyridine. Inside of a dry box, naphthylboronic acid (9.12 g, 53.0 mmol) and Na2CO3 (11.64 g, 110 mmol) are dissolved in 290 mL of degassed 4:1H2O/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(PPh3)4 in 290 mL of degassed toluene. The charged reactor is removed from the dry box, while under a blanket of N2 and is connected to the house N2 line. The biphasic solution is vigorously stirred and heated to 70° C. for 4 h. On cooling to RT, the organic phase is separated. The aqueous layer is washed with 3×75 mL of Et2O. The combined organic extracts are washed with 3×100 mL of H2O and 1×100 mL of brine and dried over Na2SO4. 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° C.
1H NMR (CDCl3) δ 7.2–8.3 (m, 10H), 10.25 (s, 1H) ppm. 13C NMR (CDCl3) 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.
6-naphthylpyridine-2-(2,6-diisopropylphenyl)imine: 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 Å molecular sieves (6 g) and 80 mg of p-TsOH. The loading of the reactor is performed under N2. The reactor is equipped with a condenser, an over head mechanical stirrer and a thermocouple well. The mixture is heated to reflux under N2 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 weighes 6.42 g. No further purification is performed. mp 142–144° C.
1H NMR (CDCl3) δ 1.3 (d, 12H), 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. 13l C NMR (CDCl3) 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.
(6-naphthyl-2-pyridyl)-N-(2,6-diisopropylphenyl)benzylamine: A 250 mL 3-neck flask, equipped with mechanical stirrer and a N2 sparge, is charged with 6-naphthylpyridine-2-(2,6-diisopropylphenyl)imine (6.19 mg, 15.8 mmol) and 80 mL of anhydrous, degassed Et2O. The solution is cooled to −78° 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  ̃50 mL of aq. NH4Cl. The organic layer is separated, washed with brine and H2O, then dried over Na2SO4. 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× ̃25 mL batches, using half of the hexane stock solution for each run. 7.0 g of the oil is isolated (93% yield).
1H NMR (CDCl3) δ 0.90 (d, 12H), 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. 13C NMR (CDCl3) 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.
Catalyst G-(Nme2)3: The reaction is performed inside of a dry box. A 100 mL round bottom flask is charged with Hf(Nme2)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(Nme2)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%.
1H NMR (C6D6) δ 0.39 (d, 3H, 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.
Catalyst G: 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° 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.
1H NMR (C6D6) δ 0.51 (d, 3H, 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.
Synthesis of Catalyst H, FIG. 10H
To a solution of 9-bromophenanthrene (10.36 mg, 41 mmol) in 132 mL of anhydrous, degassed Et2O cooled to −40° C. is added under N2 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° 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 Et2O cooled to −40° 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. NH4Cl, and subjected to an aqueous/organic work-up. The organic washes are combined and dried over Na2SO4. 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° 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° C.
1H NMR (C6D6) δ 1.08 (dd, 12H), 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. 13C NMR (CDCl3) 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.
Catalyst H-(Nme2)3: Inside of a dry box, six different teflon-screw capped, glass pressure tube reactors are each charged with Hf(Nme2)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° C. The reactor tubes are heated overnight ( ̃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  ̃125 mL of cold pentane and filtered, yielding 13.6 g of a light yellow powder for a yield of 65%.
Catalyst H: 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° 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° C. and filtered. The initially collected product is rinsed with 2×60 mL of cold pentane. 10.24 g Catalyst H is isolated (84% yield) with a purity of >99% by 1H NMR.
Synthesis of Armeenium Borate [methylbis(hydrogenatedtallowalkyl)ammonium tetrakis (pentafluoro phenyl) borate]
Armeenium borate can be prepared from ARMEEN® M2HT (available from Akzo-Nobel), HCl, and Li[B(C6F5)4] according to Example 2 of U.S. Pat. No. 5,919,983.
General 1 Gallon Continuous Solution Propylene/Ethylene
I. Copolymerization Procedure
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
II. Using Metallocene Catalyst E (Comparative)
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 13C NMR of Comparative Example 1, and it demonstrates the absence of regio-error peaks in the region around 15 ppm.
EXAMPLES 2–6
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 13C NMR sprectrum 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 2-6-1







Polymerization Conditions



















POLY



Reactor
SOLV
C2
C3
H2
LBS/HR



TEMP
FLOW
FLOW
FLOW
FLOW
production


Example
DEGC
LB/HR
LB/HR
LB/HR
SCCM
rate
















1 (com-
80.5
36.0
0.50
11.00
0
3.13


parative)


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
















TABLE 2-6-2







Monomer conversion and activity















C3/
propyl-
ethyl-




Ex-
Cat-
C2
ene
ene
catalyst
efficiency


am-
a-
ra-
conver-
conver-
concentration
g metal


ple
lyst
tio
sion
sion
ppm(metal)
per g polymer
















1
E
22.00
25.7%
64.8%
2.6
6,145,944


(com-


para-


tive)


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
















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
(° C.)
(° C.)
(° 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
—
—
















TABLE 2-6-4







Summary of Polymer Analysis Data cont'd














ΔHc
Cryst. (%)
Tm,p
Tm,e
ΔHf
Cryst. (%)


Example
(J/g)
(from Hc)
(° C.)
(° 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
—
—
—
—
—
—
















TABLE 2-6-5







Summary of Polymer Analysis Data cont'd













Ex-
Ethyl-
Ethyl-

Mn
Mw



am-
ene
ene
Regio-errors
(kg/
(kg/


ple
(wt %)*
(mol %)*
14–16 ppm(mol %)*
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





*determined by NMR













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
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 13C NMR spectrum of the propylene homopolymer product of Example 7 prepared using catalyst G. FIG. 7 shows the 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. 11A–B show the DSC heating and cooling traces of the propylene homopolymer of Example 8.







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
DEGC
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
















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
(° C.)
(° C.)
(° 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
















TABLE 7-8-3







Polymer Analysis Continued


















ΔHc
Cryst. (%)
Tm,p
Tm,e
ΔHf
Cryst. (%)
Regio-errors





Example
(J/g)
(from Hc)
(° C.)
(° 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
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 13C resonance frequency of 100.4 MHz. Acquisition parameters were selected to ensure quantitative 13C data acquisition in the presence of the relaxation agent. The data was acquired using gated 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° 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° C., with periodic refluxing initiated by heat gun.
Following data collection, the chemical shifts were internally referenced to the mmmm pentad at 21.90 ppm.
For propylene/ethylene copolymers, the following procedure is used to calculate the percent ethylene in the polymer. Integral regions are determined as follows:







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









Region D is calculated as follows: D=P×(G×Q)/2.

Region E is calculated as follows: E=R+Q+(G×Q)/2.

The triads are calculated as follows:








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 %.

For this example, the triad mole fractions are calculated to be as follows:








TABLE 9-3





Triad Mole Calculation


















PPP =
0.6706



PPE =
0.1722



EPE =
0.0224



EEE =
0.0097



PEE =
0.0442



EPE =
0.0811










From this, the B value is calculated to be (0.172+0.022+0.044+0.081)/2(0.136×0.864)=1.36

In a similar manner, the B values for the following examples are calculated to be:








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
Table 10 is a summary showing the skewness index, Six, 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. 12.
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, TMax, is near 60° C. to 65° C. In the prior art, for similar levels of ethylene incorporation, this peak moves to higher elution temperatures with lower ethylene incorporation.
For conventional metallocene catalysts the approximate relationship of the mole fraction of propylene, Xp, to the TREF elution temperature for the peak maximum, TMax, is given by the following equation:

Loge(Xp)=+289/(273+Tmax)+0.74

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 theis equation:

LnP>289/(273+Tmax)+0.75








TABLE 10







Summary of Skewness Index Results














Elution






Temperature




Ethylene
of Peak




Content
Maximum


Inventive
Catalyst Type
(Mole %)
(° C.)
Inventive Six














Sample 10-1
Catalyst H
8.2
61.4
0.935


Sample 10-2
Catalyst J
8.9
60.8
−0.697


Sample 10-3
Catalyst J
8.5
61.4
−0.642


Sample 10-4
Catalyst J
7.6
65.0
0.830


Sample 10-5
Catalyst J
7.6
65.0
0.972


Sample 10-6
Catalyst J
8.6
61.4
0.804


Sample 10-7
Catalyst J
9.6
60.2
−0.620


Sample 10-8
Catalyst J
12.4
60.2
0.921


Sample 10-9
Catalyst J
8.6
60.8
−0.434


Sample 10-10
Catalyst J
8.6
62.0
1.148


Sample 10-11
Catalyst H

57.8
1.452


Sample 10-12
Catalyst J

78.2
1.006


Sample 10-13
Catalyst H
4.4
80.0
−1.021


Sample 10-14
Catalyst E
7.6
80.6
−1.388


Sample 10-15
Catalyst E
10.0
70.4
−1.278


Sample 10-16
Catalyst E
10.7
66.2
−1.318


Sample 17-17
Catalyst F
11.1
69.2
−1.296


Sample 17-18
Catalyst E
10.6
65.6
−1.266









EXAMPLE 11
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.
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: ° 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.
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° 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° C./min from an upper temperature of at least 210° C. to a lower temperature of 0° 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° C. or lower (i.e., the final temperature of the previous step) to 210° C. or higher at a constant rate of 10° 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.
The output data from DSC consists of time (sec), temperature (° 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° 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.
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, Tmax (° 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, Δhm (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)max (W/g) at the peak melting temperature; (4) the peak specific heat flow normalized by the specific heat of melting, {(dq/dt)max/Δhm} (sec−1); (5) the first moment T1 of the melting endotherm, defined and calculated as described below; (6) the variance V1 (° C.2) of the melting endotherm relative to the first moment T1, defined and calculated as described below; and (7) the square root of the variance, V11/2 (° C.), which is one measure of the breadth of the melting endotherm.
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 T1 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
      =
    
  
  ⁢
  
    
      ∫
      
        
          T
          ·
          
            (
            
              
                d
                q
              
              /
              
                d
                t
              
            
            )
          
        
        ⁢
        
          d
          t
        
      
    
    
      ∫
      
        
          (
          
            
              d
              q
            
            /
            
              d
              t
            
          
          )
        
        ⁢
        
          d
          t
        
      
    
  




The variance V1 relative to the first moment is then standardly defined as:





  
    V
    1
  
  =
  
    
      ∫
      
        
          
            
              (
              
                T
                -
                
                  T
                  1
                
              
              )
            
            2
          
          ·
          
            (
            
              
                d
                q
              
              /
              
                d
                t
              
            
            )
          
        
        ⁢
        
          d
          t
        
      
    
    
      ∫
      
        
          (
          
            
              d
              q
            
            /
            
              d
              t
            
          
          )
        
        ⁢
        
          d
          t
        
      
    
  




Both V1 and V11/2 are measures of the breadth of the melting endotherm.

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).
Differences in melting behavior are most easily seen with the aid of figures. FIG. 13 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.
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.
FIGS. 18–22, 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.
FIG. 14 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.
FIG. 15 which shows a plot of the temperature T1% 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 Δhm divided by 165 J/g. And, with this conversion factor, 1% residual crystallinity corresponds to 1.65 J/g. Therefore, T1% c is defined as the upper limit for partial integration of the melting endotherm such that Δhm 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 the copolymers catalyzed with a nonmetallocene, metal-centered, heteroaryl ligand catalyst, 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 T1% c is similar to that of the final temperature of melting Tme.
FIG. 16, 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.
FIG. 17, 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.
FIG. 18 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 ° C.) is significantly lower than for metallocene polymers.
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 11-1







Melting Results from DSC
















ethylene
Δhm
Tmax
T1
(dq/dt)max/Δhm
V1
T1%c
Rf


Sample*
(mole %)
(J/g)
(° C.)
(° C.)
(sec−1)
(° C.2)
(° 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


11-1-22a
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 Rf: weight % crystallinity per ° C.













TABLE 11-2







Broadening of the Melting Endotherm













Starting
Fraction
Fraction
Fraction
Fraction



Crystallinity
Melted
Melted
Remaining
Remaining


Sample
(weight %)
at T1 −30° C.
at T1 −20° C.
at T1 +20° C.
at T1 +30° C.





11-2-8 (inventive)
43.2
0.153
0.229
0.249
0.134


11-2-22a (comparative)
43.3
0.040
0.112
0.019
0.004


11-2-11 (inventive)
31.8
0.143
0.235
0.221
0.131


11-2-25 (comparative)
33.9
0.103
0.170
0.127
0.009









EXAMPLE 12
Table 12 reports the haze, blooming, flex modulus and ductile-to-brittle-transition temperature (DBTT) performance of a number of different blends comprising a crystalline polypropylene matrix and an impact modifying polymer dispersed phase. The composition of the blend components and the protocols for preparing and testing the blends are reported after Table 12.
The data in Table 12 shows that high MFR elastomers do not bloom if they are crystalline (compare Samples 12–2/3 with 12–4/5/6); low MFR elastomers do not bloom (compare Samples 12–2/3 with 12–1 and 12–7/8) and the haze of the blend is even lower if the elastomer is also crystalline (compare Samples 12–2/3 with 12–7/8); and high MFR elastomers do not bloom if they are crystalline (compare Samples 12–9/10/11 with 12–12/13/14/15/16/17. The difference between blooming and nonblooming reported in Table 12 occurs between 0.030–0.040 mg/3 g. The measurement of blooming was made 48 hours after the blends were injection molded.















TABLE 12





Sample


Ratio (wt)
Haze
Blooming
Blooming
Flex Modulus
DBTT ° C.,


Number
Matrix
Elastomer
Matrix/Elastomer
(%)
mg/3 g
Visual
Kpsi
Dyn























12-1
Profax SR256M
P/E via CGC Catalyst
90/10
28
0.030
Non-blooming
113
−2




(16 mol % E, 2 MFR, 0%




crystallinity)


12-2
Profax SR256M
P/E via CGC Catalyst
90/10
25
0.100
Blooming
105
−2




(30 mol % E, 61 MFR, 0%




crystallinity)


12-3
Profax SR256M
P/E via CGC Catalyst
90/10
22
0.076
Blooming
113
−10




(40 mol % E, 87 MFR, 0%




crystallinity)


12-4
Profax SR256M
P/E via Metallocene Catalyst
90/10
13
0.017
Non-blooming
151
5




(10.6 mol % E, 186 MFR, 40%




crystallinity)


12-5
Profax SR256M
P/E via Metallocene Catalyst
90/10
13
0.019
Non-blooming
141
3




(10.6 mol % E, 33 MFR, 37%




crystallinity)


12-6
Profax SR256M
P/E via Metallocene Catalyst
90/10
14
0.003
Non-blooming
147
8




(10.6 mol % E, 21 MFR, 38%




crystallinity)


12-7
Profax SR256M
P/E via Catalyst H
90/10
12
0.023
Non-blooming
125
−1




(15.8 mol % E., 2 MFR, 16%




crystallinity)


12-8
Profax SR256M
P/E via Catalyst H
90/10
15
0.024
Non-blooming
120
−5




(18.6 mol % E, 2 MFR, 2%




crystallinity)


12-9
H308-02Z
P/E via Catalyst H
85/15
20
0.017
Non-blooming
147
10




(14.3 mol % E, 25 MFR, 21%




crystallinity)


12-10
H314-02Z
P/E via Catalyst H
85/15
19
0.025
Non-blooming
161
12




(14.3 mol % E, 75 MFR, 20%




crystallinity)


12-11
H308-02Z
P/E via Catalyst H
85/15
17
0.016
Non-blooming
176
20




(11.5 mol % E, 25 MFR, 31%




crystallinity)


12-12
H308-02Z
P/E via Catalyst H
85/15
28
0.045
Blooming
158
−2




(30 mol % E, 25 MFR, 0%




crystallinity)


12-13
H308-02Z
P/E via Catalyst H
85/15
27
0.058
Blooming
155
−5




(30 mol % E, 75 MFR, 0%




crystallinity)


12-14
H308-02Z
P/E via CGC Catalyst
85/15
25
0.040
Blooming
140
10




(16 mol % E, 25 MFR, 0%




crystallinity)


12-15
H308-02Z
P/E via CGC Catalyst
85/15
33
0.068
Blooming
141
10




(16 mol % E, 75 MFR, 0%




crystallinity)


12-16
H308-02Z
P/E via CGC Catalyst
85/15
24
0.060
Blooming
137
10




(4 mol % E, 25 MFR, 0%




crystallinity)


12-17
H308-02Z
P/E via CGC Catalyst
85/15
38
0.086
Blooming
138
10




(4 mol % E, 75 MFR, 0%




crystallinity)









The blends identified in Table 12 were prepared using the following materials:

    
    
        Profax SR256M, a 3 wt % ethylene random copolymer with MFR=2 g/10 min (MFR is Melt Flow Rate measured according to ASTM D1248 with a 2.16 kg weight at 230° C.).
        Dow Polypropylene Resin H308-02Z, a 0.5 wt % ethylene random copolymer with MFR=2 g/10 min, and nucleated with 2000 ppm NA-11 (methylene-bis-(4,6-di-tert-butylphenyl) phosphate sodium salt manufactured by Asahi Denka).
    
    


Blends of SR256M and elastomer were prepared in a 90/10 weight ratio, and blends of H308-02Z and elastomer were prepared in a 85/15 weight ratio. The blending procedure was the following:

    
    
        Either 1) the pellets of the desired composition were tumble blended for 3 minutes in the presence of Irganox B225 in a sufficient amount to result in 1000 ppm in the final composition; or 2) the desired composition was mixed using a Kobelco batch mixer at 165–175° C. for 3 minutes at a torque of 16–22%.
        The resulting blended compositions were extruded on a 30 mm Werner & Plfeiderer extruder with a temperature profile of 100/160/180/190/200° C., a screw speed of 300 rpm and a feed rate of 25 lbs/hr, resulting in a torque of 50%.
        The resulting blends were injection molded and analyzed for haze (ASTM D1003). Blooming resistance is qualitatively measured by visual inspection of injection molded haze plaques after aging for two weeks; blooming appears as a milky layer on the surface that can be scratched or washed off.

Surface Wash of Polypropylene Samples

    
    


In order to understand the amount of material that was blooming to the surface, a consistent procedure was used to conduct a surface wash of the polypropylene material:
One-millimeter polypropylene plaques were injection molded as haze plaques according to ASTM D-1003. Three grams (+/−0.002) of the pressed plaque was added to a clean 40-milliliter glass vial. 10 milliliters of chloroform was added to the vial and the vial was swirled for 3 minutes. After 3 minutes, the chloroform was quickly decanted into a clean 20-milliliter glass vial (leaving the plaque behind). The 20-milliliter glass vial containing the chloroform solution was then set on a hotplate at 58 degrees Celsius for approximately 2 hours in a fume hood to evaporate the chloroform. The samples were inspected visually to ensure complete evaporation. After evaporation, 1.6 milliliters +/−0.02 milliliter of 1,2,4-trichlorobenzene was then added to the 20-milliliter vial and the vial was swirled gently. The solution was allowed to equilibrate for 10 minutes on the hot plate set at 160 degrees Celsius. The 1,2,4-trichlorobenzene solution in the 20-milliliter vial was then decanted into a 2-milliliter glass vial for injection onto the chromatographic system.
Description of Conventional GPC System for Polypropylene Analysis
The chromatographic system consisted of a Polymer Laboratories Model PL-210 high-temperature chromatograph. The column and carousel compartments were operated at 160° C. The carousel warm-zone was set to 145° C. The columns used were 4 Polymer Laboratories 20-micron Mixed-A columns. The solvent used was 1,2,4 trichlorobenzene. The samples were prepared at a concentration of 0.15 grams of polymer in 50 milliliters of solvent. The solvent used to prepare the samples contained 200 ppm of butylated hydroxytoluene (BHT). Samples were prepared by agitating lightly for 2 hours at 160° C. The injection volume used was 100 microliters and the flow rate was 1.0 milliliters/minute.
Calibration of the GPC column set was performed with narrow molecular weight distribution polystyrene standards purchased from Polymer Laboratories. The polystyrene standard peak molecular weights were converted to polypropylene molecular weights by way of the Mark-Houwink coefficients according to the following equation:




  
    
      
        
          M
          polyolefin
        
        =
        
          
            [
            
              
                
                  k
                  polystyrene
                
                ⁢
                
                  
                    M
                    polystyrene
                  
                  
                    
                      a
                      polystyrene
                    
                    +
                    1
                  
                
              
              
                k
                polyolefin
              
            
            ]
          
          
            1
            
              
                a
                polyolefin
              
              +
              1
            
          
        
      
    
  
  
    
      
        
          
            
              
                where
                :
                
                  LogK
                  ⁢
                  
                    
                  
                  ⁢
                  polystyrene
                
              
              =
              
                -
                3.900
              
            
          
          
            
              apolystyrene
              =
              
                0.702
                ⁢
                
                  
                
                ⁢
                and
              
            
          
        
        
          
            
              
                
              
              ⁢
              
                
                  LogK
                  ⁢
                  
                    
                  
                  ⁢
                  polyolefin
                
                ⁢
                
                  
                
                =
                
                  -
                  3.721
                
              
            
          
          
            
              apolyoefin
              ⁢
              
                
              
              =
              0.725
            
          
        
      
    
  




Polypropylene equivalent molecular weight calculations using the Mark-Houwink ratioing method were performed using Viscotek TriSEC software Version 3.0.

Numerical Quantification of GPC Chromatogram into Mass Recovery

The refractometer area was obtained by integrating an internal polypropylene sample of 239,000 molecular weight. The refractometer area was used to calculate a “mass constant” for the refractive index detector (converting the refractometer signal in mV to concentration units) for the polypropylene unknown samples using the equation listed below:




  
    Mass
    ⁢
    
      
    
    ⁢
    Constant
  
  =
  
    
      
        ∑
        
          i
          =
          0
        
        npts
      
      ⁢
      
        
      
      ⁢
      
        
          RI
          i
        
        *
        FlowRate
        *
        Collection
        ⁢
        
          
        
        ⁢
        Rate
      
    
    
      Injection
      ⁢
      
        
      
      ⁢
      Volume
      *
      Concentration
      *
      
        
          d
          n
        
        /
        
          d
          c
        
      
    
  




where the mass constant is in mV/RIU, RI is in mV, flowrate is in ml/min, collection rate is in min/pt, injection volume is in ml, concentration is in mg/ml, dn/dc is in RIU×ml/mg.

The mass recovered for a specific sample is then obtained by rearranging the previous equation in the form shown below:




  
    Mass
    ⁢
    
      
    
    ⁢
    Recovered
  
  =
  
    Injection
    ⁢
    
      
    
    ⁢
    Volume
    *
    Concentration
    ⁢
    
      
        
          ∑
          
            i
            =
            0
          
          npts
        
        ⁢
        
          
        
        ⁢
        
          
            RI
            i
          
          *
          FlowRate
          *
          Collection
          ⁢
          
            
          
          ⁢
          Rate
        
      
      
        Mass
        ⁢
        
          
        
        ⁢
        Constant
        *
        
          
            d
            n
          
          /
          
            d
            c
          
        
      
    
  




The mass recovery was chosen as the material that was detected by the refractometer containing a substantial molecular weight (>1,600 MW based on the Conventional GPC calibration).

Conversion of GPC Mass Recovery into Percent of Polypropylene Mass Blooming from Film Material

    1) The mass recovery of the material was divided by the known injection volume (0.100+/−0.003 milliliters: verified by filling the loop with water, weighing, and cutting to a precise length) of the chromatographic material to convert it to concentration units.
    2) The mass of film (3000 milligrams) was divided by the 1.6 milliliters of 1,2,4 trichlorobenzene to produce the total concentration of film material that had the potential to dissolve.
    3) The result of step (1) was divided by the result of step (2) and multiplied by 100 to yield the percent mass blooming from the film material.


EXAMPLE 13
The blends listed in Table 13 below were prepared using the following materials:

    
    
        Profax SR256M is described in Example 12.
        A propylene-ethylene elastomer prepared via CGC catalysis in a solution process, containing 16 mol % ethylene with MFR=2 g/10 min.
        A propylene-ethylene elastomer prepared via Catalyst H catalysis in a solution process, containing 16 mol % ethylene with MFR=2 g/10 min.
    
    


Blends of SR256M and the Catalyst H catalyzed elastomer were prepared in a 90/10 and a 80/20 weight ratio. Blends of SR256M and the CGC catalyzed elastomer were also prepared in a 90/10 and a 80/20 weight ratio. The blending procedure was as follows:

    
    
        the pellets of the desired composition were tumble blended for 3 minutes in the presence of Irganox B225 in a sufficient amount to result in 1000 ppm in the final composition
        the tumble blended compositions were extruded on a 30 mm Wemer&Plfeiderer extruder with a temperature profile of 100/160/180/190/200° C., a screw speed of 300 rpm and a feed rate of 25 lb/hr, resulting in a torque of 50%.
        The resulting blends were injection molded and analyzed for haze (ASTM D1003), flexural modulus (ASTM 0790-970 and ductile-to-brittle-transition temperature (DBTT) by Dynatup impact (ASTM D3763-97a).
    
    















TABLE 13








Ratio








(wt)
DBTT
Flex.



Sample


Matrix/
(° C.,
Mod.
Haze


Number
Matrix
Elastomer
Elastomer
Dyn)
(kpsi)
(%)





















21-1
Profax
P/E via Cata-
90/10
0
121
17



SR256M
lyst H (16




mol % E, 2




MFR)


21-2
Profax
P/E via CGC
90/10
−2
113
28



SR256M
Catalyst (16




mol % E, 2




MFR)


21-3
Profax
P/E via Cata-
80/20
−5
90
14



SR256M
lyst H (16




mol % E, 2




MFR)


21-4
Profax
P/E via CGC
80/20
−10
84
34



SR256M
Catalyst (16




mol % E, 2




MFR)









Blend 13-1 shows much lower haze compared to blend 13-2 and slightly better modulus; the same is true for blend 13-3 versus blend 13-4 (comparison of blends containing the same rubber content, and containing rubbers that have the same ethylene content but were prepared via different catalysis).
Also, blend 13-3 shows better haze and better impact than blend 13-2 (both blends containing the same rubber composition but in different amounts and the rubbers prepared by different catalysis).
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.

## Claims

1. An impact-resistant polymer blend comprising (i) a crystalline polypropylene matrix having a weight average molecular weight, and (ii) a copolymer impact modifier having (a) a percent crystallinity of about 40 to >0, and (b) a weight average molecular weight lower than the weight average molecular weight of the crystalline polypropylene matrix the impact modifier prepared using a metallocene catalyst and comprising propylene and ethylene and/or one or more unsaturated comonomers, the matrix and the modifier each having an MFR and the MFR of the modifier at least 10 times larger than the MFR of the matrix.

2. The polymer blend of claim 1 in which the crystalline polypropylene matrix is a homopolymer.

3. The polymer blend of claim 1 in which the crystalline polypropylene matrix is a copolymer.

4. The polymer blend of claim 1 in which the unsaturated comonomer is a C4-20 α-olefin or diene.

5. The polymer blend of claim 1 in which the impact modifier is at least one of a copolymer of propylene and ethylene or a terpolymer of propylene, ethylene and a C4-20 α-olefin or diene.

6. The polymer blend of claim 1 in which the impact modifier is characterized as (A) 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 wt. % of the polymer.

7. The polymer blend of claim 1 in which the impact modifier is characterized as comprising at least about 60 weight percent (wt %) of units derived from propylene and about 0.1–40 wt % of units derived from an unsaturated comonomer other than ethylene.

8. The polymer blend of claim 1 in which the impact modifier has a melt flow rate of about 0.02 to 100 g/10 min.

9. The polymer blend of claim 8 in which the crystalline polypropylene matrix comprises at least about 80 percent by weight based upon the total weight of the blend.

10. The polymer blend of either claim 6 in which one or both of the crystalline polypropylene and impact modifier is in combination with one or more other polymers.

11. The polymer blend of claim 7 in which one or both of the crystalline polypropylene and impact modifier is in combination with one or more other polymers.

12. An article comprising the polymer blend of claim 1.

13. An article comprising the polymer blend of claim 6.

14. An article comprising the polymer blend of claim 7.

15. A blow molded article comprising the polymer blend of claim 6.

16. A blow molded article comprising the polymer blend of claim 7.

17. The blend of claim 1 in which the MFR of the at least partially crystalline copolymer impact modifier is at least 30 times larger than the MFR of the crystalline polypropylene matrix.

18. The blend of claim 7 in which the MFR of the at least partially crystalline copolymer impact modifier is at least 30 times larger than the MFR of the crystalline polypropylene matrix.