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    • 专利摘要:
    pro-catalyst composition for polymerizing the olefin monomer and process for producing an olefin-based polymer, pro-catalyst compositions having an internal electron donor which includes a substituted amide ester and optionally an electron donor component are disclosed. the ziegler-natta catalyst compositions containing the present pro-catalyst compositions exhibit improved catalyst activity and / or improved catalyst selectivity and produce propylene-based olefins with a wide molecular weight distribution.
    公开号:BR112012021399B1
    申请号:R112012021399
    申请日:2011-02-24
    公开日:2020-01-21
    发明作者:X Shu James；Gao Kuanqiang；Chen Linfeng；W Leung Tak；Tao Tao
    申请人:Dow Global Technologies Llc；Grace W R & Co；
    IPC主号:
    专利说明:

    “PRO-CATALYST COMPOSITION TO POLYMERIZE THE OLEPHINE MONOMER AND PROCESS TO PRODUCE A POLYMER BASED ON OLEFINE”
    Background [001] The present disclosure relates to procatalyst compositions containing a substituted amide ester, incorporating it into catalyst compositions and the process for producing olefin-based polymer using the aforementioned catalyst compositions and the resulting olefin-based polymers produced from them.
    [002] The global demand for olefin-based polymers continues to grow as applications for these polymers become more diverse and more sophisticated. Olefin-based polymers with wide molecular weight distribution (MWD), for example, find increasing applications in thermoforming; tube, foam, blow molding; and films, Ziegler-Natta catalyst compositions are known for the production of olefin-based polymers, particularly propylene-based polymers, with wide MWD. Ziegler-Natta catalyst compositions typically include a procatalyst composed of a transition metal halide (i.e., titanium, chromium, vanadium) supported on a metal or metalloid compound, such as magnesium chloride or silica, the complexed pro-catalyst with a co-catalyst such as an organoaluminium compound. The production of olefin-based polymers with wide MWD produced using a Ziegler-Natta catalyst, however, is typically limited to a single reactor process requiring rigorous process control and / or a series reactor process requiring multiple reactors.
    [003] Given the perennial emergence of new applications for olefin-based polymers, the technique recognizes the need for olefin-based polymers with improved and varied properties. The desirable would be a
    Petition 870190091950, of 16/09/2019, p. 14/56
    2/43 Ziegler-Natta catalyst composition that produces polymer based on olefin, and polymer based on propylene in particular, with wide molecular weight distribution (MWD) with less procedural restrictions and less equipment.
    Summary [004] The present disclosure is directed to pro-catalyst compositions containing substituted amide ester as an internal electron donor and the application thereof in catalyst compositions and polymerization processes. Catalyst compositions containing the substituted amide ester find application in olefin polymerization processes. The present catalyst compositions containing substituted amide ester have high catalyst activity and / or high selectivity and produce olefins based on propylene with high isotacticity and wide distribution of molecular weight.
    [005] In one configuration, a pro-catalyst composition is provided. The pro-catalyst composition includes a combination of a portion of magnesium, a portion of titanium and an internal electron donor. The internal electron donor includes a substituted amide ester. The substituted starch ester has the structure (II)
    below.
    (II) [006] Ri-Re are the same or different. Each Ri-Re is selected from hydrogen and a hydrocarbyl group having 1 to 20 carbon atoms. At least one of Ri-R 6 is a hydrocarbyl group having at least two carbon atoms. Alternatively, each of R3 and Rs is a hydrocarbyl group having 1 to 20 carbon atoms. R11-R13 and R21-R23 are the same or different. Each of R11-R13 and R21 Petition 870190091950, of 16/09/2019, p. 15/56
    3/43
    R23 is selected from hydrogen and a hydrocarbyl group having 1 to 20 carbon atoms.
    [007] In one configuration, another pro-catalyst composition is provided. The pro-catalyst composition includes a combination of a portion of magnesium, a portion of titanium and an internal electron donor. The internal electron donor includes a substituted amide ester. The substituted starch ester has the structure (II) below.
    (II)
    Ri-R 6 , R11-R13, and R21-R23 are the same or different. Each of R1-R6, R11R13, and R21-R23 is selected from hydrogen and a hydrocarbyl group having 1 to 20 carbon atoms. At least one of Ri-Re is a hydrocarbyl group having 1 to 20 carbon atoms. At least one of R11-R13, R21-R23 is a hydrocarbyl group having 1 to 20 carbon atoms.
    [008] In one configuration, a catalyst composition is provided. The catalyst composition includes a pro-catalyst composition. The pro-catalyst composition includes a substituted amide ester of structure (II). The pro-catalyst composition also includes a co-catalyst.
    [009] In one embodiment, a process for producing an olefin-based polymer is provided. The process includes contacting, under polymerization conditions, an olefin with a catalyst composition comprising a substituted amide ester, and forming an olefin-based polymer.
    [0010] An advantage of the present disclosure is the provision of an improved pro-catalyst composition.
    Petition 870190091950, of 16/09/2019, p. 16/56
    An advantage of the present disclosure is the provision of an improved catalyst composition for the polymerization of olefin-based polymers.
    [0012] An advantage of the present disclosure is a catalyst composition that produces a propylene-based polymer with a wide molecular weight distribution and / or high isotacticity.
    [0013] An advantage of the present disclosure is a catalyst composition that produces a propylene-based polymer with wide molecular weight distribution in a single reactor.
    Detailed Description [0014] The present disclosure provides a procatalyst composition. In one embodiment, a pro-catalyst composition is provided and includes a combination of a portion of magnesium, a portion of titanium and an internal electron donor. The internal electron donor includes a substituted amide ester. In other words, the pro-catalyst composition is a product of the reaction of a pro-catalyst precursor, a substituted amide ester, an optional halogenating agent, and an optional titanating agent.
    [0015] The pro-catalyst composition is produced by halogenating / titanating a pro-catalyst precursor in the presence of the internal electron donor. As used herein, an "internal electron donor" is a compound added or otherwise formed during the formation of the procatalyst composition that donates at least one electron pair to one or more metals present in the resulting pro-catalyst composition. The internal electron donor includes the substituted amide ester. Not wishing to be supported by any particular theory, it is believed that during halogenation and titanation the internal electron donor (1) regulates the formation of active sites, (2) regulates the position of titanium in the magnesium-based support and thereby reinforces the stereoselectivity of
    Petition 870190091950, of 16/09/2019, p. 17/56
    5/43 catalyst, (3) facilitate the conversion of the portions of magnesium and titanium in the respective halides and (4) regulate the crystallite size of the magnesium halide support during conversion. Therefore, the provision of the internal electron donor produces a pro-catalyst composition with enhanced stereoselectivity.
    [0016] The pro-catalyst precursor can be a magnesium portion compound (MagMo), a metal compound mixed with magnesium (MagMix), or a magnesium chloride compound containing benzoate (BenMag). In one configuration, the pro-catalyst precursor is a magnesium portion precursor (“MagMo”). The precursor to “MagMo” contains magnesium as the only metallic component. The MaMo precursor includes a portion of magnesium. Non-limiting examples of suitable magnesium moieties include anhydrous magnesium chloride and / or its alcohol adduct, magnesium alkoxide or aryloxide, mixed magnesium alkoxide halide, and / or carbonated magnesium dialoxide or aryloxide. In one configuration, the MagMo precursor is a magnesium (C1-4) di-alkoxide. In an additional configuration, the MagMo precursor is dietoxymagnesium.
    [0017] MagMix includes magnesium and at least one other metal atom. The other metal atom can be a main group metal or a transition metal, or an element IIIB-VIIIB transition metal. In one configuration, the transition metal is selected from Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Y, Zr, Nb, and Hf. In an additional configuration, the MagMix precursor is a magnesium / titanium (“MagTi”) compound. The precursor to “MagTi” has the formula MgdTi (ORe) fXg where Re is an aliphatic or aromatic hydrocarbon radical having 1 to 14 carbon atoms or COR 'where R' is an aliphatic or aromatic hydrocarbon radical having 1 to 14 atoms of carbon; each ORe group is the same or different; X is independently chlorine, bromine or iodine, preferably chlorine; d is 0.5 to 56, or 2 to 4; f is 2 to 116 or 5 to 15; and g is 0.5 to 116, or 1 to 3.
    Petition 870190091950, of 16/09/2019, p. 18/56
    6/43 [0018] In one configuration, the pro-catalyst precursor is a magnesium chloride material containing benzoate. As used here, a "magnesium chloride containing benzoate" ("BenMag") is a magnesium chloride pro-catalyst (i.e., a halogenated pro-catalyst precursor) containing an internal benzoate electron donor. BenMag material can also include a titanium portion, such as a titanium halide. The internal benzoate donor is unstable and can be replaced by other electron donors during pro-catalyst synthesis. Non-limiting examples of suitable benzoate groups include ethyl benzoate, methyl benzoate, ethyl p-methoxybenzoate, methyl p-ethoxybenzoate, ethyl p-ethoxybenzoate, ethyl p-chlorobenzoate. In one configuration, the benzoate group is ethyl benzoate. Non-limiting examples of BenMag procatalyst precursors include catalysts from the trade names SHAC® 103 and SHAC® 310 available from The Dow Chemical Company, Midland, Michigan.
    [0019] In one configuration, the BenMag pro-catalyst precursor is a halogenation product of any pro-catalyst precursor (i.e., a MagMo precursor or a MagMix precursor) in the presence of a benzoate compound with the structure (I)
    r 4 (I) where R1-R5 are H, a C1-C20 hydrocarbyl group that may contain heteroatoms including F, Cl, Br, I, O, S, N, P, and Si, and R 'is a C1C20 hydrocarbyl group which may optionally contain heteroatom (s) including F, Cl, Br, I, O, S, N, P, and Si. Preferably, R1-R5 is selected from H and a C1-C20 and R 'alkyl group is selected from a C1-C20 alkyl group and an alkoxyalkyl group.
    Petition 870190091950, of 16/09/2019, p. 19/56
    7/43 [0020] Halogenation / titanation of the pro-catalyst precursor in the presence of the internal electron donor produces a pro-catalyst composition that includes a combination of a magnesium portion, a titanium portion, and the electron donor internal (a substituted amide ester). In one configuration, the portions of magnesium and titanium are respective halides, such as magnesium chloride and titanium chloride. Supported by no particular theory, magnesium halide is believed to be a support on which the titanium halide is deposited and within which the internal electron donor is incorporated.
    [0021] The resulting pro-catalyst composition has a titanium content of about 1.0 weight percent to about 6.0 weight percent, based on the total weight of solids, or about 1.5 weight percent to about 5.5 weight percent, or about 2.0 weight percent to about 5.0 weight percent. The weight ratio of titanium to magnesium in the solid procatalyst composition is suitably between about 1: 3 and about 1: 160, or between about 1: 4 and about 1:50, or between about 1: 6 and 1:30. The internal electron donor is present in an amount of about 0.1% by weight to about 20.0% by weight, or from about 1.0% by weight to about 15% by weight. The internal electron donor may be present in the pro-catalyst composition in an internal electron donor to magnesium molar ratio of about 0.005: 1 to about 1: 1, or from about 0.01: 1 to about 0.4: 1. The weight percentage is based on the total weight of the pro-catalyst composition.
    [0022] The ethoxide content in the pro-catalyst composition indicates the complete conversion of precursor metal ethoxide to a metal halide. The substituted amide ester helps to convert ethoxide to halide during halogenation. In one embodiment, the pro-catalyst composition includes from about 0.01% by weight to about 1.0% by weight, or from about 0.05% by weight to about 0.5% by weight.
    Petition 870190091950, of 16/09/2019, p. 20/56
    8/43 weight of ethoxide. The weight percentage is based on the total weight of the pro-catalyst composition.
    [0023] In one configuration, the internal electron donor is a mixed internal electron donor. As used herein, an "internal mixed electron donor" is (i) a substituted amide ester, (ii) an electron donor component that donates an electron pair to one or more metals present in the resulting pro-catalyst composition, and (iii) optionally other components. In one configuration the electron donor component is benzoate, such as ethyl benzoate and / or methoxypropan-2-yl benzoate. The pro-catalyst composition with the mixed internal electron donor can be produced using the pro-catalyst production procedure as previously disclosed. In one configuration, benzoate is introduced from the addition of benzoate during the production of the pro-catalyst. In another configuration, the benzoate comes from the BenMag pro-catalyst precursor. In yet another configuration, benzoate comes from the decomposition of a portion of the substituted amide ester electron donor.
    [0024] The internal electron donor includes the substituted amide ester and
    optionally an electron donating component. In one configuration, the substituted amide ester has the structure (II) below:
    (II) where R1-R6 are the same or different. Each of R1-R6 is selected from hydrogen and a hydrocarbyl group having 1 to 20 carbon atoms. At least one of R1-R6 is a hydrocarbyl group having at least 2 carbon atoms.
    Petition 870190091950, of 16/09/2019, p. 21/56
    9/43
    Alternatively, each of R3 and R5 is a hydrocarbyl group having 1 to 20 carbon atoms. Each of R11-R13 and R21-R23 are the same or different and selected from hydrogen and a hydrocarbyl group having 1 to 20 carbon atoms.
    [0025] As used here, the term "hydrocarbyl" or "hydrocarbon" is a substituent containing only hydrogen and carbon atoms, including branched or unbranched, saturated or unsaturated, cyclic, polycyclic, fused, or acyclic species, and combinations of the same. Non-limiting examples of hydrocarbyl groups include alkyl, cycloalkyl, alkenyl, alkadienyl, cycloalkenyl, cycloalkylenyl, aryl, aralkyl, alkylaryl, and alkynyl groups.
    [0026] As used herein, the term "substituted hydrocarbyl" or "substituted hydrocarbon" is a hydrocarbyl group that is substituted with one or more non-hydrocarbyl substituent groups. A non-limiting example of a non-hydrocarbyl substituent group is a heteroatom. As used here, a "heteroatom" is an atom other than carbon or hydrogen. The heteroatom can be a non-carbon atom of Groups IV, V, VI, and VII of the Periodic Table. Non-limiting examples of heteroatoms include: halogens (F, Cl, Br, I), N, O, P, B, S, and Si. A substituted hydrocarbyl group also includes a halohydrocarbyl group and a silicon-containing hydrocarbyl group. As used here, the term "halohydrocarbyl" is a hydrocarbyl group that is replaced with one or more halogen atoms. As used here, the term "silicon-containing hydrocarbyl group" is a hydrocarbyl group that is replaced with one or more silicon atoms. The silicon atoms (s) may or may not be present in the carbon chain.
    [0027] In one configuration, at least two, or at least three, or at least 4, of R1-R6 are a hydrocarbyl group having at least 2 carbon atoms.
    Petition 870190091950, of 16/09/2019, p. 22/56
    10/43 [0028] In one configuration, each of R1 and R2 is a hydrocarbyl group with at least two, or at least three, or at least four, or at least five, or at least six, carbon atoms.
    [0029] In one configuration, each of R1 and R2 is selected from an isopropyl group, an isobutyl group, a sec-butyl group, a cyclopentyl group, a cyclohexyl group, and combinations thereof.
    [0030] In one configuration, at least one of R1 and R2 is an isopropyl group. In an additional configuration, each of R1 and R2 is an isopropyl group.
    [0031] In one configuration, at least one of R1 and R2 is an isobutyl group. In an additional configuration, each of R1 and R2 is an isobutyl group.
    [0032] In one configuration, at least one of R1 and R2 is a cyclopentyl group. In an additional configuration, each of R1 and R2 is a cyclopentyl group.
    [0033] In a configuration, each of R1 and R2 is a cyclohexyl group. In an additional configuration, each of R1 and R2 is a cyclohexyl group.
    [0034] In one configuration, at least one of R11-R13 and at least one of R21-R23 is a hydrocarbyl group having 1 to 20 carbon atoms.
    [0035] In one configuration, each of R12 and R22 is a hydrocarbyl group having at least 2 carbon atoms.
    [0036] In one configuration, the substituted amide ester has the structure (II) below:
    (II)
    Petition 870190091950, of 16/09/2019, p. 23/56
    11/43 where R1-R6 are the same or different. Each of R1, R2, R4, and R6 is selected from hydrogen and a hydrocarbyl group having 1 to 20 carbon atoms. Each of R3 and R5 is selected from a hydrocarbyl group having 1 to 20 carbon atoms. Each of R11-R13 and R21-R23 are the same or different and selected from hydrogen and a hydrocarbyl group having 1 to 20 carbon atoms.
    [0037] In one configuration, each of R1, R2, R4, and R6 is hydrogen. Each of R3 and R5 is selected from a hydrocarbyl group having 1-6 carbon atoms. In an additional configuration, each of R3 and R5 is a methyl group.
    [0038] The present disclosure provides another composition of procatalyst. In one embodiment, a pro-catalyst composition is provided and includes a combination of a portion of magnesium, a portion of titanium and an internal electron donor. The internal electron donor includes an amide ester substituted from the structure (II):
    (II) where R1-R6, R11-R13, and R21-R23 are the same or different. Each of R1R6, R11-R13, and R21-R23 is selected from hydrogen and a hydrocarbyl group having 1 to 20 carbon atoms. At least one of R1-R6 is a hydrocarbyl group having 1 to 20 carbon atoms. In addition, at least one of R11-R13 and / or at least one of R21-R23 is a hydrocarbyl group having 1 to 20 carbon atoms.
    [0039] In one configuration, each of R1, R2, R12, and R22 is a methyl group.
    Petition 870190091950, of 16/09/2019, p. 24/56
    12/43 [0040] In one configuration, each of R1 and R2 is a methyl group and each of R12 and R22 is an ethyl group.
    [0041] In one configuration, each of R1 and R2 is a methyl group and each of R12 and R22 is a butyl group.
    [0042] In one configuration, each of R1 and R2 is a methyl group and each of R12 and R22 is a phenyl group.
    [0043] In one configuration, at least one of R1 and R2 is selected from an isopropyl group, an isobutyl group, a sec-butyl group, a cyclopentyl group, and a cyclohexyl group. At least one of R12 and R22 is a hydrocarbyl group having 1-6 carbon atoms.
    [0044]
    In one configuration, each of R1 and R2 is an isopropyl group, and each of R12 and R22 is a methyl group.
    [0045]
    In one configuration, each of R1 and R2 is an isopropyl group, and each of R12 and R22 is an ethyl group.
    [0046]
    In one configuration, each of R1 and R2 is an isobutyl group, and each of R12 and R22 is a methyl group.
    [0047]
    In one configuration, each of R1 and R2 is an isobutyl group, and each of R12 and R22 is an ethyl group.
    [0048]
    In one configuration, each of R1 and R2 is a cyclopentyl group, and each of R12 and R22 is a methyl group.
    [0049]
    In one configuration, each of R1 and R2 is a cyclopentyl group, and each of R12 and R22 is an ethyl group.
    [0050]
    In one configuration, each of R1 and R2 is a cyclohexyl group, and each of R12 and R22 is a methyl group.
    [0051]
    In one configuration, each of R1 and R2 is a cyclohexyl group, and each of R12 and R22 is an ethyl group.
    Petition 870190091950, of 16/09/2019, p. 25/56
    13/43 [0052] In one configuration, each of R3 and R5 is a methyl group, and each of R12 and R22 is a methyl group.
    [0053] In one configuration, each of R3 and R5 is a methyl group, and each of R12 and R22 is an ethyl group.
    [0054] In one configuration, the internal electron donor and / or the mixed internal electron donor is / is phthalate free.
    [0055] In one configuration, the pro-catalyst composition is phthalate free.
    [0056] The present pro-catalyst composition can comprise two or more configurations disclosed here.
    [0057] In one configuration, a catalyst composition is provided. As used herein, "a catalyst composition" is a composition that forms an olefin-based polymer when contacted with an olefin under polymerization conditions. The catalyst composition includes a pro-catalyst composition and a co-catalyst. The pro-catalyst composition can be any of the previous pro-catalyst compositions with an internal electron donor which is a substituted amide ester of structure (II) as disclosed herein. The catalyst composition can optionally include an internal electron donor and / or an activity limiting agent.
    [0058] In one configuration, the internal electron donor of the catalyst composition is an internal electron donor mixed as disclosed above.
    [0059] The catalyst composition includes a co-catalyst. As used here, a 'co-catalyst' is a substance capable of converting the procatalyst into an active polymerization catalyst. The co-catalyst can include hydrides, alkyls, or aryls of aluminum, lithium, zinc, tin, cadmium, beryllium, magnesium, and combinations thereof. In one configuration, the co-catalyst is
    Petition 870190091950, of 16/09/2019, p. 26/56
    14/43 a hydrocarbyl aluminum compound represented by the formula RnAlX3-n where n = 1, 2 or 3, R is an alkyl, and X is a halide or alkoxide. Non-limiting examples of suitable co-catalysts include trimethyl aluminum, triethyl aluminum, triisobutyl aluminum, and tri-n-hexyl aluminum.
    [0060] In one configuration, the co-catalyst is triethyl aluminum. The molar ratio of aluminum to titanium is about 5: 1 to about 500: 1, or about 10: 1 to about 200: 1, or about 15: 1 to about 150: 1, or from about 20: 1 to about 100: 1, or from about 30: 1 to about 60: 1. In another configuration, the aluminum to titanium molar ratio is about 35: 1.
    [0061] In one configuration, the present catalyst composition includes an external electron donor. As used here, an "external electron donor" (or "EED") is an added compound independent of procatalyst formation and includes at least one functional group that is capable of donating an electron pair to a metal atom. An "external mixed electron donor" (or "MEED") is a mixture of two or more external electron donors. Supported by no particular theory, it is believed that the provision of one or more external electron donors in the catalyst composition causes the following properties of the polymer being formed: tacticality level (ie, xylene-soluble material), molecular weight (ie , melt flow), molecular weight distribution (MWD), melting point, and / or oligomer level.
    [0062] In one configuration, the external electron donor can be selected from one or more of the following: a silicon compound, a bidentate compound, an amine, an ether, a carboxylate, a ketone, an amide, a carbamate, a phosphate, a phosphite, a sulfonate, a sulfone, a sulfoxide, and any combination of the above.
    [0063] In one configuration, EED is a silicon compound having the general formula (III):
    Petition 870190091950, of 16/09/2019, p. 27/56
    15/43
    SiRm (OR ') 4-m (III) [0064] where R independently at each occurrence is hydrogen or a hydrocarbyl group or an amino, optionally substituted with one or more substituents containing one or more heteroatoms of Group 14, 15, 16, or 17. R contains up to 20 atoms not counting hydrogen and halogen. R 'is a C1-20 alkyl group, and m is 0, 1, or 2. In one configuration, R is C6-12 aryl, alkylaryl or aralkyl, C3-12 cycloalkyl, linear C1-20 alkyl or alkenyl, C312 branched alkyl , or C2-12 cyclic amino group, R 'is C1-4 alkyl, and m is 1 or 2.
    [0065] Non-limiting examples of silicon compounds suitable for EED include dialkoxysilanes, trialcoxysilanes, and tetralcoxisilanes such as dicyclopentyldimethoxysilane (DCPDMS), diisopropyldimethoxysilane, methyl (dichloroethyl), methoxy, methoxy, methoxy, methoxy, methoxy bis (trimethylsilylmethyl) dimethoxysilane, and any combination thereof.
    [0066] In one configuration, the EED is a bidentate compound. A "bidentate compound" is a molecule or compound that contains at least two oxygen-containing functional groups separated by a C2-C10 hydrocarbon chain, the oxygen-containing functional groups being the same or different and at least one oxygen-containing functional group being a group ether or a carboxylate group, the composition of bidentate excluding phthalates. Non-limiting examples of oxygen-containing functional groups suitable for the composition of bidentate include carboxylate, carbonate, ketone, ether, carbamate, amide, sulfoxide, sulfone, sulfonate, phosphite, phosphinate, phosphate, phosphonate, and phosphine oxide. One or more carbon atoms in the C2-C10 chain can be replaced with Group 14, 15, and 16 heteroatoms One or more H atoms in the C2-C10 chain can be replaced with alkyl, cycloalkyl, alkenyl, cycloalkenyl, aryl, alkylaryl , aralkyl, halogen, or
    Petition 870190091950, of 16/09/2019, p. 28/56
    16/43 functional groups containing a Group 14, 15, or 16 heteroatom. Non-limiting examples of suitable bidentate compounds include diethers, succinates, dialcoxybenzenes, alkoxy ester, and / or diol esters.
    [0067] In one configuration, the bidentate compound is a diether such as 3,3-bis (methoxymethyl) -2,5-dimethylhexane, 4,4-bis (methoxymethyl) -2,6-dimethylheptane, and 9.9 -bis (methoxymethyl) fluorene.
    [0068] In one embodiment, the bidentate compound is a diol ester such as 2,4-pentanediol di (benzoate), 2,4-pentanediol di (2-methylbenzoate), di (4-n-butylbenzoate) of 2,4-pentanediol, 2,2,4-trimethyl-1,3-pentanediol diisobutyrate and / or 2,2,4-trimethyl-1,3-pentanediol dibenzoate.
    [0069] In one configuration, carboxylate is a benzoate such as ethyl benzoate and ethyl 4-ethoxybenzoate.
    [0070] In one configuration the external electron donor is a phosphite such as trimethyl phosphate, triethyl phosphate, and / or tri-n-propyl phosphite.
    [0071] In one configuration, the external electron donor is an alkoxy ester such as methyl 1-methoxybicyclo [2.2.1] -hept-5-ene-2-carboxylate, methyl 2methoxypropionate, 2-methoxy-2-methylpropanoate methyl, and / or ethyl 3-methoxy-2-methylpropanoate.
    [0072] In one embodiment, the external electron donor is a succinate such as diethyl 2,3-diisopropyl succinate, di-butyl 2,3-diisopropyl succinate, and / or diethyl 2,3-diisobutyl succinate.
    [0073] In one configuration, the external electron donor is a dialcoxybenzene such as 1,2-diethoxybenzene, 1,2-di-n-butoxybenzene, and / or 1-ethoxy-2n-pentoxibenzene.
    [0074] In one configuration, the external electron donor is an amine such as 2,2,6,6-tetramethylpiperidine.
    Petition 870190091950, of 16/09/2019, p. 29/56
    17/43 [0075] It is further understood that the EED can be a MEED which can comprise two or more of any of the above EED compounds.
    [0076] In one embodiment, the catalyst composition includes an activity limiting agent (ALA). As used herein, an "activity limiting agent" ("ALA") is a material that reduces catalyst activity at elevated temperature (i.e., temperature greater than about 85 ° C). An ALA inhibits or otherwise prevents the polymerization reactor from deranging and ensures the continuity of the polymerization process. Typically, the activity of Ziegler-Natta catalysts increases as the reactor temperature rises. Ziegler-Natta catalysts also typically maintain high activity close to the softening point temperature of the polymer produced. The heat generated by the exothermic polymerization reaction can cause the polymer particles to form agglomerates and can ultimately lead to the interruption of continuity for the polymer production process. ALA reduces catalyst activity at elevated temperature, thereby preventing the catalyst from deranging, reducing (or preventing) particle agglomeration, and ensuring the continuity of the polymerization process.
    [0077] ALA may or may not be a component of EED and / or MEED. The activity limiting agent can be a carboxylic acid ester, a diether, a poly (alkylene glycol), a succinate, a diol ester, and combinations thereof. The carboxylic acid ester can be an aliphatic or aromatic mono or polycarboxylic acid ester. Non-limiting examples of suitable carboxylic acid esters include benzoates, C1-40 aliphatic C1-40 alkyl esters of aliphatic mono / di-carboxylic acids, C2-40 mono / polycarboxylate derivatives of (polyglycols) C2-100, (poly) glycol ethers C2-100, and any combination thereof. Additional non-limiting examples of carboxylic acid esters include laurates, myristates, palmitates, stearates, oleates, and sebacates, and mixtures thereof. In a
    Petition 870190091950, of 16/09/2019, p. 30/56
    18/43 additional configuration, ALA is ethyl 4-ethoxybenzoate or isopropyl myristate or di-n-butuyl sebacate.
    [0078] The catalyst composition can include any of the foregoing external electron donors in combination with any of the foregoing activity-limiting agents. The external electron donor and / or activity limiting agent can be added to the reactor separately. Alternatively, the external electron donor and the activity limiting agent can be mixed together in advance and then added to the catalyst composition and / or in the reactor as a mixture. In the mixture, more than one external electron donor or more than one activity limiting agent can be used. Non-limiting examples of suitable EED / ALA mixtures include dicyclopentyldimethoxysilane and isopropyl myristate; dicyclopentyldimethoxysilane and poly (ethylene glycol laurate); diisopropyl dimethoxysilane and isopropyl myristate; methylcyclohexyldimethoxysilane and isopropyl myristate; methylcyclohexyldimethoxysilane and ethyl 4-ethoxybenzoate; npropyltrimethoxysilane and isopropyl myristate; dimethyldimethoxysilane and methylcyclohexyldimethoxysilane and isopropyl myristate; dicyclopentyldimethoxysilane and tetraethoxysilane and isopropyl myristate; dicyclopentyldimethoxysilane and tetraethoxysilane and ethyl 4-ethoxybenzoate; dicyclopentyldimethoxysilane and n-propyltriethoxysilane and isopropyl myristate; dicyclopentyldimethoxysilane and isopropyl myristate and poly (ethylene glycol) dioleate; dicyclopentyldimethoxysilane and diisopropyldimethoxysilane and npropyltriethoxysilane and isopropyl myristate; and combinations thereof.
    [0079] The present catalyst composition can comprise two or more configurations disclosed here.
    [0080] In one configuration, a process for producing an olefin-based polymer is provided. The process includes contacting an olefin with a catalyst composition under polymerization conditions. The catalyst composition includes a substituted amide ester. The substituted amide ester can be
    Petition 870190091950, of 16/09/2019, p. 31/56
    19/43 any substituted amide ester of structure (II) as disclosed herein. The process additionally includes forming an olefin-based polymer.
    [0081] The catalyst composition includes a procatalyst composition and a co-catalyst. The pro-catalyst composition is any pro-catalyst composition disclosed herein and includes a substituted amide ester of structure (II) as the internal electron donor. The co-catalyst can be any co-catalyst as disclosed herein. The catalyst composition can optionally include an external electron donor and / or an activity limiting agent as previously disclosed.
    [0082] The olefin-based polymer contains substituted amide ester corresponding to the internal electron donor of structure (II) present in the pro-catalyst composition. In one embodiment, the olefin-based polymer can be a propylene-based olefin, an ethylene-based olefin, and combinations thereof. In one configuration, the olefin-based polymer is a propylene-based polymer.
    [0083] One or more olefin monomers can be introduced into a polymerization reactor to react with the catalyst and to form a polymer, or a fluid bed of polymer particles. Non-limiting examples of suitable olefin monomers include ethylene, propylene, α-olefins C4-20, such as 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1decene, 1-dodecene and the like.
    [0084] As used here, "polymerization conditions" are temperature and pressure parameters within a polymerization reactor suitable to promote polymerization between the catalyst composition and an olefin to form the desired polymer. The polymerization process can be a gas phase, paste, or mass polymerization process, operating in one, more than one, polymerization reactor. Consequently, the polymerization reactor can be
    Petition 870190091950, of 16/09/2019, p. 32/56
    20/43 a gas phase polymerization reactor, a liquid phase polymerization reactor, or a combination thereof.
    [0085] It is understood that the supply of hydrogen in the polymerization reactor is a component of the polymerization conditions. During polymerization, hydrogen is a chain transfer agent and affects the molecular weight (and correspondingly the melt flow rate) of the resulting polymer. The polymerization process can include a prepolymerization step and / or a pre-activation step.
    [0086] In one configuration, the process includes mixing the external electron donor (and optionally the activity limiting agent) with the pro-catalyst composition. The external electron donor and / or the activity limiting agent can be complexed with the co-catalyst and mixed with the pro-catalyst composition (pre-mix) prior to contact between the catalyst composition and the olefin. In another configuration, the external electron donor and / or the activity limiting agent can be added independently to the polymerization reactor.
    [0087] In one configuration, the olefin is propylene and optionally ethylene and / or 1-butene. The process includes forming a propylene-based polymer (propylene homopolymer or propylene copolymer) having one or more of the following properties:
    • a melt flow rate (MFR) of about 0.01 g / 10 min to about 800 g / 10 min, or about 0.1 g / 10 min to about 200 g / 10 min, or from about 0.5 g / 10 min to about 150 g / 10 min, or from about 1 g / 10 min to about 70 g / 10 min;
    • a soluble content in xylene of about 0.5% to about 10%, or from about 1% to about 8%, or from about 1% to about 4%;
    Petition 870190091950, of 16/09/2019, p. 33/56
    21/43 • a polydispersity index (PDI) of about 5.0 to about 20.0, or from about 6.0 to about 15, or from about 6.5 to about 10, or about 7.0 to about 9.0;
    • when a comonomer is present it is present in an amount of about 0.001% by weight to about 20% by weight, or from about 0.01% by weight to about 15% by weight, or about 0 , 1% by weight to about 10% by weight (based on the total weight of the polymer); and / or • internal electron donor (substituted amide ester) or mixed internal electron donor (substituted amide ester and a benzoate) present from about 1 ppb to about 50 ppm, or from about 10 ppb to about 25 ppm , or from about 100 ppb to about 10 ppm.
    [0088] The present disclosure provides another process for producing an olefin-based polymer. In one embodiment, a process for producing an olefin-based polymer is provided which includes contacting propylene with a catalyst composition comprising a substituted amide ester of structure (II) to form a propylene-based polymer. The contact between propylene and the catalyst composition occurs in a first polymerization reactor under polymerization conditions. The process further includes contacting ethylene and optionally at least one other olefin in the presence of the propylene-based polymer. The contact between the ethylene, the olefin (s), and the propylene-based polymer occurs in a second polymerization reactor under polymerization conditions and forms a propylene impact copolymer.
    [0089] In one configuration, the first reactor and the second reactor operate in series with which the effluent from the first reactor (ie, the propylene-based polymer) is loaded into the second reactor. Additional olefin monomer is added to the second polymerization reactor to continue polymerization. Additional catalyst composition (and / or any combination of
    Petition 870190091950, of 16/09/2019, p. 34/56
    22/43 individual catalysts - that is, pro-catalyst, co-catalyst, EED, ALA) can be added to the second polymerization reactor. The additional catalyst composition / components added to the second reactor can be the same or different from the catalyst composition / components introduced into the first reactor.
    [0090] In one configuration, the propylene-based polymer produced in the first reactor is a propylene homopolymer. The propylene homopolymer is loaded into the second reactor where ethylene and propylene are contacted with each other in the presence of the propylene homopolymer. This forms a propylene impact copolymer having a continuous phase (or matrix) of propylene homopolymer and a discontinuous phase (or rubber phase) selected from a propylene-based copolymer (i.e., a propylene / ethylene copolymer) or an ethylene-based copolymer (i.e., an ethylene / propylene copolymer). The discontinuous phase is dispersed in the continuous phase.
    [0091] The propylene impact copolymer may have an Fc value of about 1% by weight to about 50% by weight, or from about 10% by weight to about 50% by weight, or about 20 % by weight to about 30% by weight. As used here, “fraction copolymer” (“Fc”) is the percentage by weight of the discontinuous phase present in the heterophasic copolymer. The Fc value is based on the total weight of the propylene impact copolymer.
    [0092] The propylene impact copolymer can have an Ec value of about 1% by weight to about 100% by weight, or from about 20% by weight to about 90% by weight, or about 30 % by weight to about 80% by weight, or from about 40% by weight to about 60% by weight. As used here, “ethylene content” (“Ec”) is the percentage by weight of ethylene present in the discontinuous phase of the propylene impact copolymer. The EC value is based on the total weight of the batch phase (or rubber).
    Petition 870190091950, of 16/09/2019, p. 35/56
    23/43 [0093] The present processes for the production of olefin-based polymer can comprise two or more configurations disclosed here.
    Definitions [0094] All references to the Periodic Table of Elements here must refer to the Periodic Table of Elements, published by and copyrighted by CRC Press, Inc., 2003. Also, any references to Group or Groups must be to the Group or Groups reflected in this Periodic Table of the Elements using the IUPAC system to number groups. Unless otherwise noted, implied from context, or customary in the technique, all parts and percentages are based on weight. For the purposes of United States patent practice, the contents of any patent, patent application, or publication referenced here are incorporated herein by reference in their entirety (or the equivalent US version thereof is thus incorporated by reference), especially with respect to the dissemination of synthetic techniques, definitions (to the extent not inconsistent with any definitions provided here) and general knowledge of the technique.
    [0095] Any numerical range mentioned here includes all values from the lowest value to the highest value, in increments of one unit, with the proviso that there is a separation of at least 2 units between any lower value and any higher value . As an example, if it is recorded that the quantity of a component, or a value of a compositional or physical property, such as, for example, quantity of a component of the mixture, softening temperature, melt index, etc., is among 1 and 100, it is intended that all individual values, such as, 1, 2, 3, etc., and all sub-ranges, such as, 1 to 20, 55 to 70, 197 to 100, etc., are expressly listed in this specification. For values that are less than one, a unit is considered to be 0.0001, 0.001, 0.01, or 0.1, as appropriate. These
    Petition 870190091950, of 16/09/2019, p. 36/56
    24/43 are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value listed, should be considered to be expressly registered in this patent application. In other words, any numerical range mentioned here includes any value or sub-range within the registered range. Numeric ranges have been cited, as discussed here, in reference to melt index, melt flow rate, and other properties.
    [0096] The term "alkyl", as used here, is a saturated or unsaturated, branched or unbranched acyclic hydrocarbon radical. Non-limiting examples of suitable alkyl radicals include, for example, methyl, ethyl, n-propyl, i-propyl, n-butyl, t-butyl, i-butyl (or 2-methylpropyl), etc. Alkyls have 1 to 20 carbon atoms.
    [0097] The term "aryl" or "aryl group", as used here, is a substituent derived from an aromatic hydrocarbon compound. An aryl group has a total of six to twenty ring atoms, and has one or more rings that are separated or fused, and can be substituted with alkyl and / or halo groups. The aromatic ring (s) may include phenyl, naphthyl, anthracenyl, and biphenyl, among others.
    [0098] The terms "mixture" or "polymeric mixture", as used here, are a mixture of two or more polymers. Such a mixture may or may not be miscible (not separated by phases at the molecular level). Such a mixture may or may not be separated in stages. Such a mixture may or may not contain one or more domain configurations, as determined from transmission electron spectroscopy, light scattering, x-ray scattering, and other methods known in the art.
    [0099] The term "composition", as used here, includes a mixture of materials comprising the composition, as well as reaction products and decomposition products formed from the materials of the composition.
    Petition 870190091950, of 16/09/2019, p. 37/56
    25/43 [00100] The term "comprising", and derivatives thereof, are not intended to exclude the presence of any additional component, step or procedure, whether or not it is disclosed here. For the avoidance of doubt, all compositions claimed herein by the use of the term "comprising" may include any additional additives, adjuvants, or compounds, whether polymeric or otherwise, unless otherwise noted. In contrast, the term “essentially consisting of” excludes any other component, step or procedure from the scope of any following quote, except those that are not essential for operability. The term “consisting of” excludes any component, step or procedure not specifically outlined or listed. The term “or”, unless otherwise noted, refers to members listed individually as well as in any combination.
    [00101] The term "ethylene-based polymer", as used here, is a polymer that comprises a greater percentage of the weight of polymerized ethylene monomer (based on the total weight of polymerizable monomers), and optionally can comprise at least one polymerized comonomer.
    [00102] The term "olefin-based polymer" is a polymer containing, in polymerized form, a greater part of the weight percentage of an olefin, for example ethylene or propylene, based on the total weight of the polymer. Non-limiting examples of olefin-based polymers include ethylene-based polymers and propylene-based polymers.
    [00103] The term "polymer" is a macromolecular compound prepared by polymerizing monomers of the same or different types. "Polymer" includes homopolymers, copolymers, terpolymers, interpolymers, and so on. The term "interpolymer" is 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 types
    Petition 870190091950, of 16/09/2019, p. 38/56
    26/43 different from 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.
    [00104] The term "propylene-based polymer", as used here, is a polymer that comprises a major part of the percentage by weight of polymerized propylene monomer (based on the total amount of polymerizable monomers), and optionally can comprise at least one polymerized comonomer.
    [00105] The term "substituted alkyl", as used here, is an alkyl as defined above in which one or more hydrogen atoms attached to any carbon in the alkyl is / are replaced by another group such as a halogen, aryl, aryl substituted, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, haloalkyl, hydroxy, amino, phosphide, alkoxy, amino, uncle, nitro, silyl, and combinations thereof. Suitable substituted alkyls include, for example, benzyl, trifluoromethyl and the like.
    Test methods [00106] The melt flow rate (MFR) is measured according to the test method of ASTM D 1238-01 at 230 ° C with a weight of 2.16 kg for propylene based polymers.
    [00107] Soluble in Xylene (XS) is the percentage by weight of resin that remains in the solution after the resin is dissolved in hot xylene and the solution is allowed to cool to 25 ° C (XS Gravimetric method according to ASTM D5492- 06). XS is measured according to one of the following two procedures: (1) Viscotek method: 0.4 g of a polymer is dissolved in 20 ml of xylenes with stirring at 130 ° C for 30 minutes. The solution is then cooled to 25 ° C and after 30 minutes the fraction of insoluble polymer is removed by filtration. The filtrate
    Petition 870190091950, of 16/09/2019, p. 39/56
    The resulting 27/43 is analyzed by Flow Injection Polymer Analysis using a Viscotek ViscoGEL H-100-3078 column with a THF mobile phase flowing at 1.0 ml / min. The column is coupled to a Viscotek Model 302 Triple Detector Array, with light scattering detectors, viscometer and refractometer operating at 45 ° C. The calibration of the instrument was maintained with Viscotek PolyCAL® polystyrene standards. (2) NMR method: XS is measured using a 1H NMR method as described in U.S. Patent No. 5,539,309, the entire contents of which are incorporated herein by reference. Both methods are calibrated against the ASTM gravimetric method.
    [00108] The Polydispersity Index (PDI) is measured by an AR-G2 rheometer which is a dynamic voltage control spectrometer manufactured by TA Instruments using a method according to Zeichner GR, Patel PD (1981) “A comprehensive Study of Polypropylene Melt Rheology ”[A comprehensive study of polypropylene melt rheology], Proc. of the 2nd World Congress of Chemical Engineering, Montreal, Canada. An ETC oven is used to control the temperature at 180 ° C ± 0.1 ° C. Nitrogen is used to purge the interior of the oven to protect the sample from degradation by oxygen and moisture. A 25 mm diameter cone and plate sample holder pair is used. The samples are molded by compression on 50 mm x 100 mm x 2 mm plates. The samples are then cut into 19 mm squares and loaded in the center of the bottom plate. The geometries of the upper cone are (1) Cone angle: 5:42:20 (degrees: minutes: seconds); (2) Diameter: 25 mm; (3) Sectioning clearance: 149 microns. The geometry of the bottom plate is a 25 mm cylinder.
    Test procedure:
    [00109] (1) The cone and plate sample holder is heated in the ETC oven at
    180 ° C for 2 hours. Then the gap is zeroed under a sheet of nitrogen gas.
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    28/43 [00110] (2) The cone is raised to 2.5 mm and the sample is loaded on the top of the bottom plate.
    [00111] (3) Start timing for 2 minutes.
    [00112] (4) The upper cone is immediately lowered to rest lightly on the top of the sample, observing normal force.
    [00113] (5) After two minutes the sample is tightened to a gap of
    165 microns lowering the top cone.
    [00114] (6) The normal force is observed. When the normal force is below <0.05 Newton the excess sample is removed from the edge of the cone and plate sample holder by a spatula.
    [00115] (7) The upper cone is lowered again for a sectioning clearance that is 149 microns.
    [00116] (8) An Oscillatory Frequency Scan test is performed under these conditions:
    [00117] (i) Test delayed at 180 ° C for 5 minutes.
    [00118] (ii) Frequencies: 628.3 r / s to 0.1 r / s.
    [00119] (iii) Data acquisition rate: 5 points / decade.
    [00120] (iv) Request: 10% [00121] (9) When the test is completed, the transversal module (Gc) is detected by the Rheology Advantage Data Analysis program provided by TA Instruments.
    [00122] (10) PDI = 100,000 + G / cm3 (in Pa units).
    [00123] The final melting point (TMF) is the temperature to melt the most perfect crystal in the sample and is a measure for the inherent isotacticity and crystallisability of the polymer. The test is conducted using a TA Q100 Differential Scanning Calorimeter. A sample is heated from 0 ° C to 240 ° C at a rate of 80 ° C / min, cooled at the same rate to 0 ° C, then heated again at the same rate
    Petition 870190091950, of 16/09/2019, p. 41/56
    29/43 rate up to 150 ° C, maintained at 150 ° C for 5 minutes and then heated from 150 ° C to 180 ° C at 1.25 ° C / min. The MPT is determined from this last cycle by calculating the beginning of the baseline at the end of the heating curve.
    Test procedure:
    [00124] (1) Calibrate the instrument with high purity indium as standard.
    [00125] (2) Purge the instrument head / cell with a constant flow rate of 50 ml / min of nitrogen constantly.
    [00126] (3) Preparation of the sample:
    [00127] Compression mold 1.5 g of powder sample using a Wabash Compression Molder 30-G302H-18-CX (30 ton): (a) heat the mixture to 230 ° C for 2 minutes on contact; (b) compress the sample at the same temperature with a pressure of 20 ton for 1 minute; (c) cool the sample to 45 ° F and maintain for 2 minutes at a pressure of 20 ton; (d) cut the plate into 4 of approximately the same size, stack them together, and repeat steps (a) - (c) to homogenize the sample.
    [00128] (4) Weigh a piece of the sample (preferably between 5 to 8 mg) from the sample plate and seal it in a standard aluminum sample pan. Place the sealed pan containing the sample on the sample side of the instrument head / cell and place a sealed pan on the reference side. If the autosampler is used, weigh several different sample specimens and prepare the machine for a sequence.
    [00129] (5) Measurements:
    (i) Data storage: off (ii) Ramp 80.00 ° C / min to 240.00 ° C (iii) Isotherm for 1.00 min (iv) Ramp 80.00 ° C / min to 0.00 ° Ç
    Petition 870190091950, of 16/09/2019, p. 42/56
    30/43 (v) Isothermia for 1.00 min (vi) Ramp 80.00 ° C / min to 150.00 ° C (vii) Isotherm for 5.00 min (viii) Data storage: on (ix) Ramp 1.25 ° C / min to 180.00 ° C (x) End of method [00130] (6) Calculation: MPT is determined by the interception of two lines. Draw a line from the high temperature baseline. Draw another line from the deflection of the curve near the end of the curve on the high temperature side.
    [00131] By way of example and not by limitation, examples of the present disclosure will now be provided.
    EXAMPLES
    [00132] 1. Synthesis of substituted amide ester [00133] Ethyl 2-cyano-2-isobutyl-4-methylpentanoate, and ethyl 2-cyano-2isopropyl-3-methylbutyrate:
    RI, DBU, DMF
    R = i-Pr; i-Bu [00134] A 500 ml round-bottom flask is equipped with a magnetic stirrer, and is loaded with ethyl 2-cyanoacetate (11.3 g, 0.1 mol) and anhydrous DMF (120 ml). To the stirred solution a solution of 1.8 diazabicyclo [5.4.0] undec-7-ene (DBU) (30.4 g, 0.2 mol, 1.0 equiv.) In anhydrous DMF (40 ml) is added by dripping . After the addition is complete, the mixture is stirred for another hour. The flask is cooled in an ice-water bath, and a solution of the iodide (0.2 mol, 1.0 equiv.) In DMF (40 ml) is added by dripping. The mixture is raised to room temperature and stirred for another 14 hours until all the starting material is converted into the product (monitored by GC). The mixture
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    31/43 is poured into ice-water, and extracted with diethyl ether. After filtration, the filtrate is concentrated, and the residue is vacuum distilled to produce the product as a colorless liquid.
    [00135] Ethyl 2-Cyano-2-isopropyl-3-methylbutyrate: Yield 67%; 1H NMR: 04.24 (q, 2H, J = 7.0 Hz), 2.28 (heptat, 2H, J = 7.0 Hz), 1.30 (t, 3H, J = 7.0 Hz ), 1.07 (d, 6H, J = 7.0 Hz), 1.01 (d, 6H, J = 6.5 Hz).
    [00136] Ethyl 2-Cyano-2-isobutyl-4-methylpentanoate: Yield 88%; 1H NMR: δ 4.26 (q, 2H, J = 7.0 Hz), 1.82-1.90 (m, 4H), 1.63-1.70 (m, 2H), 1.34 (t, 3H, J = 7.0 Hz), 1.04 (d, 6H, J = 6.0 Hz), 0.89 (d, 6H, J = 6.0 Hz).
    O
    [00137] 2,2-disubstituted 3-aminopropanols:
    [00138] A 1,000 ml three-necked, round-neck flask purged with nitrogen is equipped with a magnetic stirrer, condenser, and funnel for pouring. Powdered aluminum lithium hydride (0.14—0.18 mol) is added followed by anhydrous THF (140 ~ 180 ml), which can be replaced with commercial 1.0 M lithium aluminum hydride in THF. While stirring, a solution of the ethyl 2-cyanocarboxylate compound (0.06 ~ 0.08 mol) in ether (~ 200 ml) is added by dripping to keep the mixture at gentle reflux. At the end of the addition, the mixture is heated to gentle reflux for 3 hours. After being cooled, the bottle is placed in an ice-water bath. Water is added carefully, and the mixture is stirred until the solid turns white. After filtration, the solid is washed with additional ether, the filtrate concentrated, and the residue dried in vacuo to produce the product as a white solid or sticky oil that can be used directly in acylation reactions without further purification.
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    32/43 [00139] 2-Aminomethyl-2-isopropyl-3-methylbutan-1-ol: Yield 71%, 1H NMR: δ 3.72 (s, 2H), 2.93 (s, 2H), 2 , 65 (br.s, 3H), 1.97 (heptat, 2H, J = 8.8 Hz), 0.95 (d, 6H, J = 8.5 Hz), 0.94 (d, 6H, J = 9.0 Hz).
    [00140] 2-Aminomethyl-2-isobutyl-4-methylpentan-1-ol: Yield 75%; 1H NMR: δ 3.54 (s, 2H), 2.77 (s, 2H), 2.65 (br.s, 3H), 1.58-1.70 (m, 2H), 1.21 (d, 2H, J = 7.0 Hz), 1.20 (d, 2H, J = 7.5 Hz), 0.88 (d, 6H, J = 8.0 Hz), 0.87 (d , 6H, J = 8.5 Hz).
    4-Aminopentan-2-ol:
    Ni-AI, KOH, h 2 o
    Tn ----- ► YY OH NH 2 [00141] A 1,000 ml round bottom flask is loaded with 3,5dimethylisoxazole (9.7 g, 0.1 mol) and water (200 ml). To this solution is added 1.0 M aqueous potassium hydroxide (200 ml). Nickel-aluminum alloy (1: 1, 32 g, 0.2 mol) is added in portions over 1 hour. After about another two hours, the reaction mixture is filtered over celite, and the solid washed with additional water. The filtrate is extracted with methylene chloride once. The aqueous solution is acidified with concentrated HCI, and concentrated to dryness. Potassium hydroxide (10 M, 5.0 ml) is added to the icoiuuu, the immaiura and extracted with methylene chloride, and the extract is dried with magnesium sulfate. After filtration, the filtrate is concentrated, the residue is dried in vacuo to produce 9.0 g (87%) of the product as a sticky oil, which is used directly in the next acylation reaction. 1H NMR (two isomers about 1: 1.3): δ 4.10-4.18 (m, 1Ha), 3.95-4.00 (m, 1HB), 3.37-3.41 ( m, 1Ha), 3.00-3.05 (m, 1Hb), 2.63 (br.s, 3Ha + 3Hb), 1.42-1.55 (m, 2Ha + 1Hb), 1,121.24 ( m, 6Ha + 7Hb).

    Acylated amino alcohols:
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    33/43 [00142] A 250 ml round bottom flask is loaded with amino alcohol (0.02 mol), pyridine (0.04 mol, 1.0 equiv.) And methylene chloride (50 ml). The flask is immersed in an ice-water bath, and benzoyl chloride (0.04 mol, 1.0 equiv.) Is added by dripping. After the addition is complete, the flask is warmed to room temperature, and the mixture is stirred overnight. Upon completion of the reaction monitored by GC, the mixture is diluted with methylene chloride, and washed with water, saturated ammonium chloride, water, saturated sodium bicarbonate, and brine, accordingly. The solution is dried over manganese sulfate, filtered, and the filtrate concentrated. The residue is purified by flash column chromatography to produce the product as a colorless oil or white solid.
    3- (4-phenylbenzamido) -2,2-dimethylpropyl 4-phenylbenzoate [00143] A 250 ml round bottom flask is loaded with 3.75 g of 2- (aminomethyl) -2-isobutyl-4-methylpentan- 1-ol, 3.24 ml of pyridine and 40 ml of methylene chloride. The flask is cooled in an ice-water bath and 8.67 g of biphenyl-4-carbonyl chloride are added in one portion. The reaction is warmed to room temperature and stirred overnight. The reaction is diluted with 100 ml of methylene chloride and subsequently washed with water, 1 N HCl (20 ml), water, saturated NaHCO3, and brine once (20 ml), the organic layer is dried over MgSO4, removed by filtration. the solid, and concentrated and purified by silica gel column chromatography to provide the desired compound as a white powder.
    [00144] 1H NMR data are obtained on a 500 MHz or 400 MHz Brüker NMR spectrometer using CDCl3 as solvent (in ppm).
    [00145] The substituted amide esters produced by the following synthesis are provided in Table 1 below.
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    34/43
    Table 1
    Esters d and amide replaced Compound Structure 1 H NMR (CDCI3 as solvent (in ppm)) (1) benzoate3-benzamido-2,2-dimethylpropyl Ογόχϊ0 O Yield 88%; δ 8.08 (d, 2H, J = 8.5 Hz), 8.85 (d, 2H, J = 8.0 Hz), 7.32-7.62 (m, 6H), 6.99 ( t, 1H, J = 6.5 Hz), 4.23 (s, 2H), 3.38 (d, 2H, J = 6.5 Hz), 1.10 (s, 6H). (2) benzoate of4-benzamidopentan-2-ila o ction 0 0 Yield 71% (two isomers with a ratio of about 2.1 to 1): isomer 1: δ 7.96 (dd, 2H, J = 10.5 Hz, 2.0 Hz), 7.68 (dd, 2H, J = 10.5, 1.5 Hz), 7.24-7.52 (m, 6H), 6.67 (m, 1H), 5,255.34 (m, 1H), 4.27-4 , 38 (m, 1H), 1.902.02 (m, 2H), 1.35 (d, 3H, J = 7.5 Hz), 1.27 (d, 3H, H = 7.5 Hz); isomer 2: δ 8.05 (dd, 2H, J = 10.5, 2.0 Hz), 7.81 (dd, 2H, J = 10.0, 2.0 Hz), 7.39-7, 56 (m, 6H), 6.40 (d, 1H, J = 9.5 Hz), 5.22 (qt, 1H, J = 7.5, 8.0 Hz), 4.28-4.40 (m, 1H), 2.12 (ddd, 1H, J = 7.5, 11.0, 17.5 Hz), 1.81 (ddd, 1H, J = 7.0, 8.5, 17, 5 Hz), 1.44 (d, 3H, J = 8.0 Hz), 1.29 (d, 3H, J = 8.5 Hz)
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    (3) benzoate2-(benzamidomethyl) -2-isopropyl-3-methylbutyl IIo o Yield 68%; δ 7.95 (dd, 2H, J = 10.0, 2.0 Hz), 7.67 (dd, 2H, J = 10.0, 2.0 Hz), 7.30-7.55 (m , 6H), 6.63 (t, 1H, J = 6.5 Hz), 4.38 (s, 2H), 3.57 (d, 2H, J = 7.5 Hz), 2.06 (heptat , 2H, J = 8.5 Hz), 1.38-1.47 (m, 4H), 1.04 (d, 12H, J = 8.5 Hz) (4) 2- benzoate(benzamidomethyl) -2-isobutyl-4methylpentyl The 0 Yield 71%; δ 8.02 (d, 2H, J = 9.5 Hz), 7.76 (d, 2H, J = 9.5 Hz), 7.39-7.60 (m, 6H), 6.84 ( t, 1H, J = 7.5 Hz), 4.30 (s, 2H), 3.47 (d, 2H, J = 8.0 Hz), 1.84 (heptat, 2H, J = 7.5 Hz), 1.38-1.47 (m, 4H), 0.96 (d, 12H, J = 8.0 Hz). (12) 4-ethylbenzoate2,2-dimethyl-3- (4ethylbenzamido) propyl O O Yield 56%; δ 7.99 (d, 2H, J = 7.5 Hz), 7.78 (d, 2H, J = 8.5 Hz), 7.25-7.29 (m, 4H), 7.00 ( t, 1H, J = 6.5 Hz), 4.20 (s, 2H), 3.36 (d, 2H, J = 6.5 Hz), 2.72 (q, 2H, J = 7.5 Hz), 2.70 (q, 2H, J = 7.5 Hz), 1.27 (t, 3H, J = 7.5 Hz), 1.26 (t, 3H, J = 7.5 Hz) , 1.08 (s, 6H).
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    (13) 4-3- (4butylbenzamido) 2,2-dimethylpropyl butylbenzoate the o Yield 57%; δ 7.97 (d, 2H, J = 10.5 Hz), 7.76 (d, 2H, J = 10.5 Hz), 7.22-7.26 (m, 4H), 6.96 ( m, 1H), 4.20 (s, 2H), 3.36 (d, 2H, J = 7.5 Hz), 2.68 (t, 2H, J = 9.5 Hz), 2.66 ( t, 2H, J = 9.5 Hz), 1,571.66 (m, 4H), 1.31-1.41 (m, 4H), 1.08 (s, 6H), 0.933 (t, 3H, J = 9.0 Hz), 0.931 (t, 3H, J = 9.0 Hz) (14) 4-3- (4phenylbenzamido) 2,2-dimethylpropyl phenylbenzoate yy x) Q 75 Γ ΐι x VO O 0 Yield 76%; 8.10 (d, J = 8.5 Hz, 2H), 7.86 (d, J = 8.0 Hz, 2H), 7.66 (d, J = 8.5 Hz, 2H), 7, 63 (d, J = 8.0 Hz, 2H), 7.59 (t, J = 7 Hz, 7H), 6.86 (br, 1H), 7.38-7.46 (m, 6H), 4.34 (s, 2H), 3.54 (d, J = 6 Hz, 2H), 1.94 (m, 2H), 1.48 (m, 4H), 1.01 (s, 6H), 1.02 (s, 6H).
    2. Preparation of the pro-catalyst [00146] A precursor of the pro-catalyst (according to the weight shown in Table 2) and 2.52 mmols of internal electron donor (ie, substituted amide ester) are loaded into a vial equipped with mechanical stirring and bottom filtration. 60 ml of a mixed solvent of TiCl4 and chlorobenzene (1/1 by volume) are introduced into the flask. The mixture is heated to 115 ° C and remains at the same temperature for 60 minutes with stirring at 250 ppm before removing the liquid by filtration. 60 ml of mixed solvent are added again and the reaction is allowed to continue at the same desired temperature for
    Petition 870190091950, of 16/09/2019, p. 49/56
    37/43 minutes with stirring followed by filtration. This process is repeated once. 70 ml of isooctane are used to wash the resulting solid at room temperature. After the solvent is removed by filtration, the solid is dried by flowing N2 or in vacuo.
    Table 2
    Pro-catalyst precursor Weight MagTi-1 (M) 3.0 g SHAC® 310 (S) 2.0 g
    [00147] MagTi-1 is a Mag / Ti precursor mixed with a composition of Mg3Ri (OEt) 8Cl2 (a MagTi precursor prepared according to example 1 in US patent No. 6,825,146) with an average particle size 50 microns. SHAC® 310 is a catalyst containing benzoate (a precursor of BenMag procatalyst with an average particle size of 27 microns) with ethyl benzoate as the internal electron donor produced according to Example 2 in US patent No. 6,825,146, the entire content of which is incorporated by reference here. The titanium content for each of the resulting procatalyst compositions is listed in Table 3. The peaks for the internal donors are designated according to the retention time from GC analysis. No further characterization is performed.
    Table 3. Pro-catalyst compositions
    Internal electron donor Catalyst precursor in Catalyst # Catalyst compositions You(%) Ethyl benzoate (%) Internal electron donor (%) DiBP ** MagTi-1 M-DiBP 2.99 0 12.49 1 ** MagTi-1 M-1 3.32 0.45 trace
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    SHAC® 310 S-1 3.07 1.08 trace 2 MagTi-1 M-2 3.27 0.53 trace 3 MagTi-1 M-3 3.14 0.17 2.98 SHAC® 310 S-3 3.53 0.93 1.92 4 MagTi-1 M-4 3.19 0.18 8.80 SHAC® 310 S-4 3.29 0.13 4.59 12 MagTi-1 M-12 3.46 0 trace SHAC® 310 S-12 3.35 1.41 trace 13 MagTi-1 M-13 3.34 0 trace SHAC® 310 S-13 1.82 1.24 trace 14 SHAC® 310 S-14 3.43 2.06 6.19
    DiBP = Diisobutyl phthalate *** Comparative sample
    3. Polymerization [00148] Polymerization is performed in liquid propylene in a 1-gallon autoclave. After conditioning, the reactors are loaded with 1,375 g of propylene and a desired amount of hydrogen and brought to 62 ° C. 0.25 mmol of DCPDMS is added to 7.2 ml of a 0.27 M triethyl aluminum solution in isooctane, followed by the addition of a 5.0 wt.% Catalyst paste in mineral oil (the actual solids weight is indicated in the data tables below). The mixture is pre-mixed at room temperature for 20 minutes before being injected into the reactor to initiate polymerization. The premixed catalyst components are flashed into the isooctane reactor using a high pressure catalyst injection pump. After exotherm, the temperature is controlled to 67 ° C. The total polymerization time is 1 hour.
    4. Polymer test
    Petition 870190091950, of 16/09/2019, p. 51/56
    39/43 [00149] Polymer samples are tested for bulk density, melt flow rate (MFR), soluble xylene (XS), polydispersity index (PDI), and final melting point (TMF). Unless specified, XS is measured using the Viscotek method.
    [00150] Substitution of the amide ester improves catalyst productivity and / or polymer properties for both the precursor of SAHC® 310 and the precursor of MagTi-1 as shown in Table 4 below.
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    Table 4
    Performance of substituted amide ester catalyst and polymer properties
    Internal electron donor Pro-catalyst precursor Example# Pro-catalyst# Pro-catalyst(mg) H2(scc) Activity(kg / g-h) BD MFR XS(%) PDI Tmf(° C) 1 MgTi-1 E-2 ** M-1 16.7 4500 8.2 0.29 4.0 4.50 9.24SHAC® 310 E-3 ** S-1 16.7 3000 12.8 0.35 1.2 3.50 * 9.00 171.64 2 MgTi-1 E-4 M-2 16.7 4500 32.0 0.33 3.5 3.37 * 5.69 171.62 SHAC® 310 E-5 S-2 8.4 3000 44.1 0.41 2.0 3.87 * 5.89 171.58 3 MgTi-1 E-6 M-3 16.7 13500 12.6 0.27 12.0 2.34 7.50 171.32 SHAC® 310 E-7 S-3 16.7 13500 22.7 0.38 7.6 3.50 9.20 171.76 4 MgTi-1 E-8 M-4 16.7 13500 14.4 0.28 7.0 2.26 6.52 171.75 SHAC® 310 E-9 S-4 16.7 13500 35.7 0.39 5.6 3.84 7.82 171.86 12 MgTi-1 E-24 M-12 16.7 13500 12.6 0.28 10.8 4.68 6.79 170.03 SHAC® 310 E-25 S-12 16.7 13500 25.2 0.37 6.8 3.29 6.93 171.54 13 MgTi-1 E-26 M-13 8.4 4500 18.1 0.28 2.4 4.01 6.42 170.88 SHAC® 310 E-27 S-13 8.4 4500 46.4 0.40 1.3 3.29171.24
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    14 SHAC® 310 E-85 S-14 8.4 20000 44.6 0.35 7.5 2.65 7.09DiBP MagTi E-1 ** M-DiBP 16.7 1500 34.4 0.4 2.5 2.98 4.81 171.48
    * By the NMR method **
    Comparative sample
    Petition 870190091950, of 16/09/2019, p. 54/56
    42/43 [00151] Simple amide ester compounds, such as compound 1 with two methyl groups on the central carbon atom (position 2) of C3 spacer between the group with amide functionality and the group with ester functionality, show low catalyst activity and low catalyst selectivity (polymer isotacticity) as well as a low final melting point (TMF). When positions 1,3 are both replaced with methyl groups (compound 2), there is a marked increase in catalyst activity and a noticeable improvement in isotacticity (Table 4), with PDI values that are still significantly higher than can be performed by a DiBP-based catalyst. Depositors have also surprisingly found that improvement in catalyst activity and / or isotacticity can also be achieved by increasing the volume of the substituents on the central carbon atoms. Examples include isopropyl (compound 3), and isobutyl (compound 4) replacing the methyl groups at position 2 (Table 4).
    [00152] Surprisingly, a significant increase in catalyst activity is also seen when the two benzoyl groups in the 3benzamido-2,2-dimethylpropyl benzoate (1) are replaced with p-ethylbenzoyl (12), pn-butylbenzyl (13) groups , or p-phenylbenzoyl (14). The increase in catalyst activity is even more profound when SHAC® 310 is used as a pro-catalyst precursor (Table 4).
    [00153] We surprisingly and unexpectedly found that the substitution on the benzoyl phenyl rings further reinforces the activity of the catalyst and selectivity of the catalyst (polymer isotacticity). In addition, the activity of the catalyst is increased and XS is reduced by introducing an alkyl group (s) into the C3 spacer.
    [00154] It is specifically intended that the present disclosure is not limited to the configurations and illustrations contained here, but includes forms
    Petition 870190091950, of 16/09/2019, p. 55/56
    43/43 modified from those configurations including portions of the configurations and combinations of elements of different configurations that fall within the scope of the following claims.
    权利要求:
    Claims (15)
    [1]
    1. Pro-catalyst composition to polymerize olefin monomer, CHARACTERIZED by the fact that said pro-catalyst composition comprises:
    a combination of a magnesium portion, a titanium portion and an internal electron donor comprising a substituted amide ester having structure (II):

    [2]
    2. Pro-catalyst composition according to claim 1, CHARACTERIZED by the fact that at least two of R-i-Re are a hydrocarbyl group having at least 2 carbon atoms.
    Petition 870190091950, of 16/09/2019, p. 10/56
    2/4
    [3]
    3. Pro-catalyst composition, according to claim 1 or 2, CHARACTERIZED by the fact that each of Ri and R2 is a hydrocarbyl group with at least two carbon atoms.
    [4]
    4. Pro-catalyst composition, according to claim 1 or 2, CHARACTERIZED by the fact that at least one of Rn, R13, R21 and R23 is a hydrocarbyl group having from 1 to 20 carbon atoms.
    [5]
    5. Pro-catalyst composition according to claim 1 or 2, CHARACTERIZED by the fact that each of R1 and R2 is selected from the group consisting of an isopropyl group, an isobutyl group, a sec-butyl group, a cyclopentyl group , and a cyclohexyl group.
    [6]
    6. Pro-catalyst composition, according to claim 1, CHARACTERIZED by the fact that each of R1, R2, R4, and Re is hydrogen and each of R3 and Rs is a methyl group.
    [7]
    7. Pro-catalyst composition to polymerize olefin monomer, CHARACTERIZED by the fact that said pro-catalyst composition comprises:
    a combination of a magnesium portion, a titanium portion and an internal electron donor comprising a substituted amide ester having structure (II):

    [8]
    8. Pro-catalyst composition according to claim 7, CHARACTERIZED by the fact that each of R1 and R2 is a methyl group and each of R12 and R22 is selected from the group consisting of ethyl, butyl, and phenyl.
    [9]
    Pro-catalyst composition according to any one of claims 1, 2 and 6 to 8, CHARACTERIZED by the fact that it comprises a mixed external electron donor comprising the substituted amide ester of structure (II) and a donor component of electrons, in which the electron donating component donates a pair of electrons to one or more metals present in the pro-catalyst composition.
    [10]
    10. Catalyst composition, CHARACTERIZED by the fact that it comprises:
    a pro-catalyst composition as defined in claim 1 or 7; and a co-catalyst.
    [11]
    11. Catalyst composition according to claim 10, CHARACTERIZED by the fact that it comprises an external electron donor selected from the group consisting of a silicon compound, a bidentate compound, a diether, a diol ester, a carboxylate, a amine, a phosphite, and combinations thereof.
    [12]
    12. Catalyst composition according to claim 10, CHARACTERIZED by the fact that it comprises two or more external electron donors of alkoxysilane.
    [13]
    13. Catalyst composition according to claim 10, CHARACTERIZED by the fact that it comprises an activity limiting agent
    Petition 870190091950, of 16/09/2019, p. 12/56
    4/4 selected from the group consisting of a carboxylic acid ester, a diether, a diol ester, and combinations thereof.
    [14]
    14. Process to produce an olefin-based polymer, CHARACTERIZED by the fact that it comprises:
    contacting, under polymerization conditions, an olefin with a catalyst composition comprising a pro-catalyst composition as defined in claim 1 or 7; and forming an olefin-based polymer comprising a substituted amide ester.
    [15]
    15. Process, according to claim 14, CHARACTERIZED by the fact that the olefin is propylene, the process comprises forming a propylene-based polymer having a polydispersity index of 5.0 to 20.0.
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    法律状态:
    2018-03-06| B25C| Requirement related to requested transfer of rights|Owner name: DOW GLOBAL TECHNOLOGIES LLC (US) |
    2018-04-10| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-06-19| B25A| Requested transfer of rights approved|Owner name: W. R. GRACE AND CO. - CONN (US) |
    2019-07-16| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|
    2019-12-17| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-01-21| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 24/02/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US30859610P| true| 2010-02-26|2010-02-26|
    PCT/US2011/026024|WO2011106494A1|2010-02-26|2011-02-24|Procatalyst composition with substituted amide ester internal electron donor|
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