Molecular weight modifier for use with lanthanide and actinide catalysts

Abstract: Lanthanide and actinide catalyst systems normally appear to be "pseudo-living" when they are used to polymerize conjugated diolefin monomers into polymers. Polymerizations which are catalyzed with such catalyst systems produce polymers which have increasingly high molecular weight as monomer conversions are increased. Consequently, any change in polymerization time or conversion may affect the polymer's ultimate molecular weight. This has made controlling the molecular weight of polymers which are made utilizing lanthanide and actinide catalysts difficult. It has been unexpectedly discovered that vinyl halides can be used as molecular weight regulators for polymerizations which are catalyzed with lanthanide and actinide catalyst systems. Accordingly, the present invention relates to a process which comprises polymerizing at least one conjugated diolefin monomer in the presence of (a) a catalyst system which is comprised of (1) an organoaluminum compound, (2) an organometallic compound which contains a metal from Group III-B of the Periodic System, and (3) at least one compound which contains at least one labile halide ion; and (b) a vinyl halide.

Description: This invention relates to a molecular weight modifier to be used in processes for polymerizing, in bulk or in solution, at least one conjugated diolefin monomer using a catalyst system based on rare earth elements, particularly lanthanides and actinides. The problem of modifying the molecular weight of the final polymers exists long since, even before the advent of the catalyst systems based on rare-earth metals. For example, at the times in which the commonly known Ziegler-Natta catalyst systems, which were mainly based on an organoaluminium compound and titanium tetrachloride, were used, an attempt towards modifying the molecular weight of the end polymer had been disclosed in DE-A-1 956 870, in which high-1,4-cis polyisoprene was obtained by a Ziegler-Natta catalyst system and the molecular weight of the isoprenepolymer was modified by replacing at least partially the hydrocarbon solvent by a vinyl halide. Additions of the vinyl halide in question, in practice, represented up to 50% by weight of a hydrocarbon solvent, a large amount, which applied to polymerizations in solution only. The use of rare-earth metals in catalyst systems for polymerizing conjugated dienes was disclosed, in 1978 by EP-A-0 11 184, which disclosed a catalyst system composed of a carboxylate of a rare-earth element having an atomic number of from 57 to 71, but the problem of regulating the molecular weight had been totally ignored and left outstanding. The subsequent experience has shown, inter alia, that the rare-earth metal based catalyst systems are "pseudo living", in that the polymers obtained with their aid have their molecular weights increased as the polymer conversions increase. The attempts to solve this problem were mainly directed towards limiting the conversions, or adjusting the catalyst concentrations, or both concurrently. This circumstance originated difficulties, especially in continuous polymerization systems, in which the residence times are difficult to control, and polymers having different molecular weights may result. High monomer conversions are always desirable, especially in bulk-polymerization runs carried out with rare-earth metal based catalyst systems, but the current demand is for low- or moderate molecular weight polymers. However, the molecular-weight modifiers as currently used with the Ziegler-Natta catalyst systems are ineffective when using rare-earth metal based catalyst systems. Alpha-olefins and non-conjugated diolefins are effective chain-transfer agents when Ziegler-Natta catalyst systems are used, as disclosed in US-A-4 383 097 and ZA-A-83/2555, but are inactive in that sense if used with rare-earth metal based catalyst systems. The molecular weight of polymers obtained with Alfin catalysts can be lowered by using 1,4-, and 1,2-dihydronaphthalene, but these compounds cannot be used with rare-earth metal based catalyst systems. Preformed rare-earth metal based catalyst systems are advantageous in use, but have the defect that they produce polymers which have molecular weights higher than those produced with non-preformed rare-earth metal based catalyst systems. With a view to solve the problem aforementioned satisfactorily, this invention provides a process for polymerizing, in bulk or in solution, at least one conjugated diolefin monomer using a catalyst system comprising: (I) an organic aluminium compound having the general formula: Al(R₁.R₂.R₃) wherein: R₁ is selected from alkyl, cycloalkyl, alkoxy, aryl, alkaryl, aralkyl and a hydrogen atom; R₂ is selected from alkyl, cycloalkyl, aryl, alkaryl, aralkyl and a hydrogen atom; R₃ is selected from alkyl, cycloalkyl, aryl, alkaryl and aralkyl; (II) an organic-metallic compound having the general formula: ML₃ wherein: M is a metal selected from Sc, Y, the metals having an atomic number from 57 to 71 inclusive (lanthanides) and the metals having an atomic number from 89 to 103 inclusive (actinides), and L is a monovalent bidentate, or a divalent bidentate, organic ligand containing from 1 to 20 carbon atoms, selected from the hydrocarbyl monocarboxylic acids and the hydrocarbyl dicarboxylic acids, and (III) at least one compound which contains at least one labile halide ion (halogen donor), selected from alkyl-, aryl-, alkaryl-, aralkyl- and cycloalkyl metal halides, wherein the metal is selected from an element of the Groups II-A, III-A and IV-A of the Periodic Table, wherein the process is carried out in the presence of an amount of from 0,05 part to 10 parts per hundred parts of monomer (phm) of: (IV) a vinyl halide, selected from vinyl bromide and vinyl chloride, as a molecular weight modifier. The Periodic Table referred to all over herein is the Chemical Abstracts System Periodic Table. The polymers obtained by the process defined in the foregoing have a large proportion of 1,4-cis structure and display low, or only moderately high, molecular weights. The conjugated diolefins which can be polymerized with the process defined above are: 1,3-butadiene; isoprene; 2-ethyl-1,3-butadiene; 1,3-pentadiene (or piperylene); 2-methyl-1,3-pentadiene; 4-butyl-1,3-pentadiene, 2,3-dimethyl-1,3-pentadiene; 1,3-hexadiene; 1,3-octadiene; 1-phenyl-1,3-butadiene, and 2-ethyl-1,3-pentadiene. The copolymers of diolefins obtained according to this invention generally contain more than 90% of their microstructures in a 1,4-configurations, the portion of the copolymer, resulting from the conjugated diolefins containing four carbon atoms in the chain, having a high cis-1,4-configuration. Representatives of the compound (I) of the catalyst system defined in the foregoing are: diethylaluminium hydride, di-n-propylaluminium hydride, di-n-butyl-aluminium hydride, diisobutylaluminium hydride, diphenylaluminium hydride, di-p-tolylaluminium hydride, dibenzylaluminium hydride, phenylethylaluminium hydride, phenyl-n-propylaluminium hydride, p-tolylethylaluminium hydride, p-tolyl-n-propylaluminium hydride, p-tolylisopropylaluminium hydride, benzylethylaluminium hydride, benzyl-n-propylaluminium hydride, and benzylisopropylaluminium hydride and other organoaluminium hydrides. Also included are ethylaluminium dihydride, butylaluminium dihydride, isobutylaluminium dihydride, octylaluminium dihydride, amylaluminium dihydride and other organoaluminium dihydrides. Also included are diethylaluminium ethoxide and dipropylaluminium ethoxide. Also included are trimethylaluminium, triethylaluminium, tri-n-propylaluminium. triisopropylaluminium, tri-n-butylaluminium, triisobutylaluminium, tripentylaluminium, trihexylaluminium, tricyclohexylaluminium, trioctylaluminium, triphenylaluminium, tri-p-tolylaluminium, tribenzylaluminium, ethyldiphenylaluminium, ethyl-di-p-tolylaluminium, ethyldibenzylaluminium, diethylphenylaluminium, diethyl-p-tolylaluminium, and diethylbenzylaluminium. In the compound (II) as defined in the foregoing, the preferred lanthanide is neodymium, and the preferred (II) compounds are neodymium-2-ethyl-hexanoate (Nd Oct), neodymium octanoate, and neodymium neodecanoate. Representatives of the ligand C₁-C₂₀ hydrocarbyl monocarboxylic acids are:acetic, propionic, valeric, hexanoic, 2-ethylhexanoic, neodecanoic, lauric, and stearic acid, and, representative of the ligand C₁-C₂₀ dicarboxylic acids are: oxalic, malonic, maleic, succinic, and o-phthalic acid. Representative of the halogen donors (III) are: ethylmagnesium bromide, butylmagnesium bromide, phenylmagnesium bromide, methylmagnesium chloride, butylmagnesium chloride, ethylmagnesium iodide, phenylmagnesium iodide, diethyl-aluminium bromide, diisobutylaluminium bromide, methylaluminium sesquibromide, diethylaluminium chloride, ethylaluminium dichloride, ethylaluminium sesquichloride, diisobutylaluminium chloride, isobutylaluminium dichloride, dihexylaluminium chloride, cyclohexylaluminium dichloride, phenylaluminium dichloride, didodecylaluminium chloride, diethylaluminium fluoride, dibutylaluminium fluoride, diethylaluminium iodide, dibutylaluminium iodide, phenylaluminium diiodide, trimethyltin bromide, triethyltin chloride, dibutyltin dichloride, butyltin trichloride, diphenyltin dichloride, and tributyltin iodide. Preferred halogen-donor among the compounds (III) is ethylaluminium dichloride (EADC). Preferred among the vinyl halides (IV) is vinyl chloride. The amount of vinyl halide utilized will vary with the molecular weight which is desired for the polymer being synthesized. Naturally, the use of greater quantities of the vinyl halide results in the production of a polymer having lower molecular weights. As a general rule, from about 0.05 to 10 phm (parts per hundred parts of monomer) of a vinyl halide will be utilized. In most cases from 0.1 phm to 2.5 phm of a vinyl halide will be present during the polymerization. Persons skilled in the art will be able to easily ascertain the amount of vinyl halide in order to produce a polymer having a specifically desired molecular weight. The rare earth metal catalysts system can be prepared using an "in situ" technique or it can be "preformed". By "in situ" is meant that the catalyst components are added separately to the monomer to be polymerized. By "preformed" is meant the manner in which the catalyst components are mixed together prior to exposure of any of the components to the monomer to be polymerized. It is also known that when employing the type of catalyst system described in this invention, the presence of monomer is not essential to the formation of an active catalyst species, thus, facilitating the use of "preformed" catalysts. Also, it is known that freshly "preformed" catalysts are frequently more active than catalysts which have been allowed to age before use. Greatly improved "preformed" catalysts can be prepared by carrying out the "preforming" in the presence of small amounts of conjugated diolefins. Preforming in the presence of mononers results in homogeneous (soluble) catalyst systems, whereas those prepared by mixing in the absence of monomers are frequently heterogeneous (insoluble). Such a "preforming" technique is described in detail in US-A-3,794,604. The proportions of the components of the polymerization catalyst compositions of this invention can be varied widely. When the halide ion of the halogen containing compound (III) is bromide, chloride or iodide ion, the atomic ration of the halide ion to the metal M of the catalytic component II can vary from 0.1/1 to 6/1. A more preferred ratio is from 0.5/1 to 3.5/1 and the most preferred ratio is 2/1. However, when the halide ion of the halogen-containing compound is fluoride ion, the ratio of the fluoride ion to the metal M of the catalytic component (II) ion ranges from 20/1 to 80/1 with the most preferred ratio being 30/1 to 60/1. The molar ratio of the trialkylaluminium or alkylaluminium hydride catalytic component (I) to the organometallic compound ML₃ (catalytic component (II)) can range from 4/1 to 200/1 with the most preferred range being from 8/1 to 100/1. The molar ratio of diolefin to the metal M can range from 0.2/1 to 3000/1, the most preferred range being from 5/1 to 500/1. The amount of catalyst charged to the reduction system can be varied over a wide range; the sole requirement being that a catalytic amount of the catalyt composition, sufficient to cause polymerization of the diolefin, be present in the reaction system. Low concentrations of catalyst are desirable in order to minimize ash problems. It has been found that polymerizations will occur when the catalyst level of the metal M of the catalytic component II varies between 0,05 and 1,0 millimole of metal M per 100 grams of monomer. A preferred ratio is between 0.1 and 0,3 millimole of the metal M per 100 grams of monomer. The concentration of the total catalyst system employed of course, depends upon factors such as purity of the system, polymerization rate desired, temperature and other factors. Therefore, specific concentrations cannot be set forth except to say that catalytic amounts are used. The polymerization of the diolefin can be carried out by utilizing a bulk polymerization procedure or a solution polymerization procedure employing suitable inert solvents. By the term "inert solvent" is meant that the solvent or diluent does not enter into the structure of, or affect adversely, the resulting polymer. Such solvents are usually aliphatic, aromatic and cycloaliphatic hydrocarbons, representative of which are pentane, hexane, heptane, benzene, toluene, and cyclohexane. The solvent/monomer volume ratio may be varied over a wide range. Up to 20 or more to 1 volume ratio of solvent to monomer can be employed. It is usually preferred, or more convenient, to use a solvent/monomer ratio of 3/1 to 6/1. In bulk polymerization procedures the reaction medium is substantially solventless and will contain no more than about 10% organic compounds which are solvents for the polymer being synthetized, based upon the total weight of the reaction medium. In most cases the reaction medium will contain less than 4% by weight solvents or virtually no solvents at all. Temperatures at which the polymerization reaction is carried out can be varied over a wide range. Usually the temperature can be varied from extremely low temperatures such as -60°C up to high temperatures such as 150°C or higher. Thus, the temperature is not a critical factor of the invention. It is generally preferred, however, to conduct the reaction at a temperature in the range of from 10°C to 90°C. The pressure at which the polymerization is carried out can also be varied over a wide range. The reaction can be conducted at atmospheric pressure or, if desired, it can be carried out at sub-atmospheric or super-atmospheric pressure. Generally, a satisfactory polymerization is obtained when the reaction is carried out at about autogenous pressure, developed by the reactants under the operating conditions used. This invention is illustrated by the following examples. Unless specifically indicated otherwise, parts and percentages are given by weight. A polymer's molecular weight can be designated in terms of diluite solution viscosity (DSV), inherent viscosity, Mooney viscosity, number average molecular weight (M n ) and weight average molecular weight (M w ). In the following examples dilute solution viscosities were determined in 0,1 to 0,5 weight percent toluene solutions at 30°C. Mooney viscosities were determined using a large rotor a one minute warm-up time and a four minute running time at 100°C. The number and weight average molecular weights reported were determined using a Waters™ GPC Model No. 150C gel permeation chromatograph instrument with the polymers dissolved in chloroform. EXAMPLES 1-9 A butadiene in hexane solution was passed down a column containing silica gel powder, and measured quantities of the solution were charged into a series of 118 ml (four ounce) bottles. The solutions were dry nitrogen for 25 s after which they contained about ten grams of butadiene per 100 ml of solution in each bottle. Incremental amounts of one of three potential molecular weight modifying agents were charged to each of these solutions, except for the first one, which served as a control, as shown in Column 3 of Table I. The catalyst components were charged to each bottle by the "in situ" method as follows; (a) 0,92 ml of 0,87 molar triisobutylaluminum (TIBAL) in hexane, (b) 0,43 ml of 0,058 molar neodymium 2-ethyl hexanoate (Nd Oct) and (c) 0,10 ml of 0.25 molar ethylaluminum dichloride (EADC) in hexane. The bottles then were capped tightly using a rubber liner and a Teflon seal. The bottles were placed in a water bath controlled to 50°C and were rotated end-over-end for the length of time listed in Table I. The polymerizations were terminated by injecting 0,05 g of 2,4,6-tris-(dimethylaminomethyl)-phenol, 0,1 g dibutyl-para-cresol and 0,5 ml methanol in hexane solution. The polymer solutions were placed in Petri dishes and were air and then vacuum dried. The addition of 2.500 to 10.000 parts per million of vinyl chloride to the butadiene resulted in lowering the molecular weight of the resulting polybutadienes as evidenced by both inherent viscosities (DSV) and the weight average molecular weights as determined by gel permeation chromatographic analyses presented in columns 6 and 7 in Table I. On the other hand, chloroethane and 1,4-dihydronaphtalene were ineffective as molecular weight modifiers. EXAMPLES 10-16 A homogeneous "preformed" catalyst was prepared in the presence of butadiene as follows: 12 ml of a 2,45 molar solution of dry butadiene in hexane were injected by syringe into a dry, nitrogen-flushed 118 ml glass bottle containing a magnetic stirring bar; 37,2 ml of a 1,2 molar solution of diisobutylaluminium hydride in hexane were added; 5,2 ml of 0,66 molar neodymium octoate in hexane were injected slowly with stirring and with brief cooling in a beaker of ice water; and 13,4 ml of 0,25 molar ethylaluminium dichloride solution were injected slowly with stirring. This catalyst solution (A) was allowed to stand at room temperature for three hours before it was utilized in the following experiments. 6,95 grams of vinyl chloride was injected by syringe into a capped 118 ml bottle containing 48,57 grams of dry hexane. This was calculated to contain 8,58 weight/volume percent of vinyl chloride in hexane. Then 3,3 ml of preformed catalyst solution A was injected into a dry, nitrogen-flushed bottle, followed by 8 ml of the vinyl chloride in hexane solution in order to determine whether the preformed catalyst would remain active after standing in the presence of vinyl chloride. This was labelled catalyst solution B. One hundred mls of a dry butadiene in hexane solution containing 13,3 grams of butadiene were charged to each of a series of seven 118 ml bottles. The first bottle served as a control. Incremental amounts of the vinyl chloride in hexane solution ranging between 1.000 and 25.000 parts per million of vinyl chloride based upon the weight of butadiene were injected by syringe into five bottles of butadiene in hexane. Then 0,66 ml of preformed catalyst solution A was injected into each of these six bottles of premix, and 2.3 ml of catalyst B was injected into the seventh bottle. Fresh bottle caps were used to seal the bottles which then were tumbled end-over-end end at 50°C in a water bath for one hour, except that the bottle in Example No. 15 was permitted to remain for 70 min. The polymerizations were terminated as described for Examples 1 through 9. The results are shown in Table II. Example Vinyl Chloride, ppm Catalyst Polymer Yield, wt % DSV dl/g 10 0 A 87 2,58 11 1.000 A 87,5 2,27 12 2.500 A 85 - 13 5.000 A 86 2,28 14 10.000 A 81 2,14 15 25.000 A 85 2,23 16 10.000 B 80 2,28 EXAMPLES 17-26 A homogeneous "preformed" catalyst was prepared in the presence of some butadiene as follows: 60 ml of a 2,2 molar solution of butadiene in hexane were injected by syringe into a dry, nitrogen-flushed 240 ml glass bottle; 94,5 ml of a 2,2 molar solution of diisobutylaluminum hydride in hexane were added; 12,3 ml of 0,66 molar solution of neodymium octoate in hexane were injected slowly with stirring by a magnetic stirring bar; and 32,4 ml of 0,25 molar ethylaluminium dichloride solution in hexane were injected slowly with stirring and with slight cooling. This catalyst solution was permitted to stand at room temperature for 36 days before it was used in the experiments described herein. One hundred mls of a dry butadiene in hexane solution containing 13,3 grams of butadiene were charged to each of a series of 118 ml bottles. Incremental amounts ranging between 1.000 to 25.000 parts per million of five unsaturated halocarbons were injected by syringe into the butadiene in hexane solutions. The halocarbons were diluted with hexane to prepare a 5 to 7 weight/volume percent solution before injection into the premix. Thus, 3 ml, or 4,55 grams, of vinyl bromide were injected into a bottle containing 65 ml of dry hexane to prepare a 6,8 wt/vol percent solution of vinyl bromide in hexane. The appropriate amounts of this solution were injected into the butadiene in hexane solutions to prepare the concentrations indicated in Colomn 2 of Table III. Then 0,78 ml aliquots of the catalyst described in the first paragraph was injected into each bottle, which then was sealed with a fresh cap and liner. The concentration of catalyst components was about Bd/DIBA-H/NdOct/EADC - 4/3,35/0,24/0,24 millimoles/100 g of butadiene. All bottles were placed in a water bath which was controlled at 50°C, and tumbled end-over-end for one hour (except Bottle Nos. 22 and 26 were polymerized for 2,5 h and 2 h, respectively). The polymerizations were terminated with 2,4,6-tris-(dimethylaminomethyl)-phenol, isopropanol and dibutyl-para-cresol. The addition of vinyl bromide to butadiene lowered the molecular weight of the polybutadiene prepared in its presence, as shown by data for DSV's, and number average and weight average molecular weights in Table III. Other unsaturated halocarbons, including beta-bromostyrene, vinylidene chloride, 2-chloropropene and 2-chloro-2-butene were not effective. Example Additive, ppm in Bd Polymer wt. g DSV dl/g Mol Wt x 10⁻³ Mn Mw Comparative 17 Control 0 9,51 7,5 482 1194 18 Vinyl Br 1.000 8,43 6,5 208 1070 19 Vinyl Br 2.500 7,43 6,8 270 1075 20 Vinyl Br 5.000 6,90 6,0 314 1057 21 Vinyl Br 10.000 6,55 5,8 232 1008 22 Vinyl Br 25.000 8,60 4,9 180 903 comparative 23 Beta-Br Styrene 2.500 8,75 7,6 ND ND comparative 24 Vinylidene Cl 2.500 9,39 7,6 ND ND comparative 25 2-Cl-Propene 2.500 8,11 7,9 ND ND comparative 26 2-Cl-Butene 2.500 9,24 7,2 ND ND ND= Not Determined Beta-Br Styrene = Beta-Bromostyrene Vinylidene Cl = Vinylidene Chloride Vinyl Br = Vinyl bromide 2-Cl-Propene = 2-Chloropropene 2-Cl-Butene = 2-Chlorobutene Examples 27-31 Neat butadiene was polymerized in the presence of vinyl bromide, and in quantities large enough that Mooney viscosities could be determined on the resulting polybutadienes. Approximately 100 g of rubber grade butadiene were charged to each of a series of dry, nitrogen-flushed, tared, 950 ml glass bottles, to which a magnetic stirring bar had been added, and which then were sealed with perforated metal crown caps and a rubber liner. Incremental amounts of vinyl bromide were injected by syringe into the butadiene. The catalyst components were charged by the "in situ" method by injecting (1) 1,75 ml of a 1,2 molar solution of diisobutylaluminum hydride in hexane, (2) 1,0 ml of 0,10 molar neodymium neodecanoate in hexane and (3) 0,4 ml of 0,25 molar ethylaluminium dichloride in hexane into the butadiene in each bottle while the contents were agitated by the magnetic stirring bars. The bottles were then placed in hot (48°C) water in polyethylene containers on magnetic stirrers for one hour. The stirring bars stopped rotating after about 13 to 23 min due to the formation of almost solid polymer. The bottles and contents were very hot, although the water jacket temperature did not reflect this, and actually had cooled to about 44°C after one hour. The polymerizations in Example Nos. 27-30 were terminated after one hour, and Example No. 31 after 1,75 h, by injecting 24 ml of a hexane solution containing 1,2 g each of 2,4,6-tris-(dimethylamino-methyl)phenol and dibutyl-para-cresol into each of the polymers. The sharply lower molecular weights for the polymers prepared in the presence of vinyl bromide are shown by the data in Table IV. Example Charge. g Polymer wt. g DSV, dl/g Mooney Visc Mol Wt X 10⁻³ Bd VinylBr Mn Mw comparative 27 99,6 0(control) 30,7 4,9 56 87 635 28 100 0,55 33,4 2,7 37 56 438 29 99,6 1,0 80,5 2,8 33 59 410 30 100 2,15 84,5 2,4 31.5 72 432 31 100 5,5 70,5 2,5 30 65 397 The microstructures of Polymer Nos. 27 and 31 as determined by infrared spectroscopic analyses were 98% cis-1,4-PBd, 1% trans-1,4- and 1% 1,2 PBD, and 97% cis-1,4-PBd, 1% trans-1,4- and less than 1% 1,2-PBd, respectively. This indicates that the vinyl bromide has no significant effect upon the microstructure. EXAMPLES 32-33 Neat butadiene was polymerized in somewhat larger quantities by charging approximately 900 grams of dry, liquid butadiene into a 2,5 l horizontal, cylindrical steel reactor. This reactor was a laboratory kneading reactor which was sealed with a flanged plate through the centre of which a high torque drive mechanism was attached to the agitator shaft. A glass plate or sight glass covered the end of the cylinder. There was an electric heating jacket around the reactor cylinder which permitted warming the monomer to 50°C prior to initiating the neat polymerization reaction. A cylindrical tube containing a cooling coil was mounted vertically on top of the reactor cylinder. Butadiene and other monomers or desired hydrocarbons were added to the reactor by "bombing" them through a line entering the bottom of this column and into the top of the reactor. Catalyst subsequently was charged through this same line. Coolant was toluene which was chilled in a dry ice-acetone bath and then circulated through the cooling coil. Monomers and other hydrocarbon vapors were condensed and flowed back into the reactor from the cooling column. The reactor pressure (and simultaneously, the reactor temperature) was controlled at 4,8 bar ± 0,2 bar, (70 psig ± 2 psig) and the temperature at 50°C plus or minus 2°C by manually adjusting the pumping rate of the coolant. A second line also entered near the bottom of the condensing (reflux) column and into the top of the reactor. Polymer stabilizers (stopping agent and antioxidant) were bombed into the reactor througt this line when it was desired to terminate the polymerization. Agitation was provided by radial disk shaped elements, which were attached to the rotating horizontal shaft, and which were equipped with mixing and kneading bars. Two rows of two stationary counter-paddles were attached to the inside wall of the cylinder in the areas not wiped by the mixing and kneading bars. The counter-paddles were set so as to scrape and clean the agitator shaft and its disk shaped elements. The interaction of the rotating disks and mixing bars with the counter-paddles provided the good kneading and mixing of the viscous polymer and catalyst, and later of the polymer with the polymer stabilizers, and at the same time provided self-cleaning of the metal surfaces. A preformed catalyst was charged to the reactor to initiate polymerizatian. The preformed catalyst was prepared in a dry 118 ml glass bottle containing a magnetic stirring bar by charging (1) 1,0 ml of a 2,45 molar solution of butadiene in hexane, (2) 23,4 ml of a 1,2 molar solution of diisobutylaluminum hydride in hexane, and with nixing and moderate cooling, (3) 4,3 ml of 0,66 molar neodymium octoate in hexane and (4) 11,2 ml of 0,25 molar ethylaluninum dichloride solution in hexane. Then 39 ml of the freshly preformed catalyst was withdrawn into a syringe, and was charged into a small, dry, nitrogen flushed steel bomb. The preformed catalyst solution the was charged into the cylindrical reactor under nitrogen pressure. Polymerization was permitted to continue until only a single (solid) phase was visible through the glass plate. The polymerization was terminated by forcing about 5 ml of isopropanol plus a solution containing 7 ml of tris-(dimethylaminomethyl)-phenol plus 6,75 grams of dibutyl-para-cresol dissolved in 200 ml of liquid butadiene into the reactor under nitrogen pressure. After the stabilization solution had mixed with the polymer for about 10 min, the pressure on the reactor was gradually released permitting the non-polymerized hydrocarbons to evaporate. The recovered polymer was dried further at 66,65 h Pa residual pressure (710 mmHg of vacuum) and 50°C for at least 15 h. The polymer yield obtained in Example No. 32--a control experiment--was 732 g, or 81,5 percent conversion. Example No. 33 was conducted in a very similar manner except that after charging the butadiene to the reactor, 19 grams or vinyl chloride was forced with nitrogen pressure into the reactor before the contents were warmed to 50°C and prior to adding the catalyst. A comparison of the results presented in Table V demonstrate the effect of vinyl chloride to lower the polymer molecular weight. An infrared analysis of the polymer prepared in Example 33 showed that its microstructure was 98% cis-1,4-PBd. 1% trans-1,4-PBd and less than 1% 1,2-PBd. Thus the vinyl chloride had no effect upon the microstructure of the polymer. Pzn Example Charge. g Time Min Polymer Yield.g Mooney Visc DSV, Dl/g Mol wt x 10⁻³ Bd Vinyl Cl Mn Mw Comparative 32 899 0(control) 16,5 732 107 3,3 181 562 33 897 19 13,0 666 57 2,3 130 443 Examples 34-41 A premix solution containing about 133 grams of isoprene per liter of solution in hexane was prepared, passed down a silica gel column, and sparged with nitrogen. Aliquots of 100 ml of this solution were dispensed into a series of eight narrow-mouthed 118 ml bottles. A preformed catalyst was prepared in the same manner and proportions of catalyst components as described in Example Nos. 32 and 33. Example Halide added, ppm to isoprene Yield wt % DSV, dl/g Comparative 34 none (control) 36 5,35 35 2.500 V a Cl 35 5,2 36 5.000 V Cl 36 5,1 37 10.000 V Cl 36 4,8 38 2.500 V Br 36 5,6 39 5.000 V Br 30 4,7 40 10.000 V Br 27 4,5 Comparative 41 10.000 Benzyl Cl 36 not analyzed a - V = vinyl The amounts of organic halides listed in the second column of Table VI were injected as solutions in hexane, as described in Example Nos. 10-16, into the bottles of isoprene in hexane premix. Them, 0,58 ml of the preformed catalyst was injected. This amount was equivalent to a catalyst charge of Bd/DIBA-H/NdOct/EADC = 2/2,5/0,25/0,25 millimol per 100 grams of isoprene. The bottles were recapped and placed in a polymerization bath controlled at 50°C where the contents were tumbled end-over-end. As the polymerizations progressed, viscous cements formed in all bottles except for the instance where benzyl chloride had been added. In this case, the polyisoprene was insoluble in hexane and small solid particles of it tumbled in semi-suspension. The polymerizations were terminated after four hours (16 hours in Example No. 41) by adding 0,06 g of 2,4,6-tris-(dimethlaminomethyl)phenol and 0,12 g of dibutyl-para-cresol in hexane solution. The data in the last column in Table VI illustrate that the presence of either vinyl chloride or vinyl bromide during polymerization lowers the molecular weights (DSV) of the resulting polyisoprenes. The vinyl halides had no effect upon the polymer microstructure. However, the benzyl chloride apparently resulted in numerous radicals which caused cyclization of the polyisoprene.

Claims: Process for polymerizing, in bulk or in solution, at least one conjugated diolefin monomer using a catalyst system comprising: (I) an organic aluminium compound having the general formula: Al(R₁.R₂.R₃) wherein: R₁ is selected from alkyl, cycloalkyl, alkoxy, aryl, alkaryl, aralkyl and a hydrogen atom; R₂ is selected from alkyl, cycloalkyl, aryl, alkaryl, aralkyl and a hydrogen atom; R₃ is selected from alkyl, cycloalkyl, aryl, alkaryl and aralkyl; (II) an organic-metallic compound having the general formula: ML₃ wherein: M is a metal selected from Sc, Y, the metals having an atomic number from 57 to 71 inclusive (lanthanides) and the metals having an atomic number from 89 to 103 inclusive (actinides), and L is a monovalent bidentate, or a divalent bidentate, organic ligand containing from 1 to 20 carbon atoms, selected from the hydrocarbyl monocarboxylic acids and the hydrocarbyl dicarboxylic acids, and (III) at least one compound which contains at least one labile halide ion (halogen donor), selected from alkyl-, aryl-, alkaryl-, aralkyl- and cycloalkyl metal halides, wherein the metal is selected from an element of the Groups II-A, III-A and IV-A of the Periodic Table, characterized in that it is carried out in the presence of an amount of from 0,05 part to 10 parts per hundred parts of monomer (phm) of: (IV) a vinyl halide, selected from vinyl bromide and vinyl chloride, as a molecular weight modifier. Process according to Claim 1, wherein the amount of the vinyl halide is from 0,1 phm to 2,5 phm. Process according to Claim 1, wherein the vinyl halide is vinyl chloride. Process according to Claim 1, wherein the conjugated-diolefin monomer is selected from: 1,3-butadiene; isoprene; 2-ethyl-1,3-butadiene; 1,3-pentadiene; 2-methyl-1,3-pentadiene; 4-butyl-1,3-pentadiene, 2,3-dimethyl-1,3-pentadiene; 1,3-hexadiene; 1,3-octadiene; 1-phenyl-1,3-butadiene, and 2-ethyl-1,3-pentadiene.

Inventors: THROCKMORTON MORFORD CHURCH, THROCKMORTON, MORFORD CHURCH
Applicants: ENICHEM ELASTOMERS, GOODYEAR TIRE & RUBBER, ENICHEM ELASTOMERI S.R.L., THE GOODYEAR TIRE & RUBBER COMPANY
Application year: 1987
Main classification: C08F36
IPC codes: C08F4, C08F236, C08F36